SEBU7600-12 M Telehandler

8/9/2019 SEBU7600-12 M Telehandler

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®© 2010 CaterpillarAll Rights Reserved

MAINTENANCE INTERVALSOperation and MaintenanceManual Excerpt


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SEBU7600-12

March 2009

Operation andMaintenance

ManualTH350B, TH355B, TH360B and TH460BTelehandlers

SLD1-Up (Machine)SLE1-Up (Machine)

SLF1-Up (Machine)JRK1-Up (Machine)

SAFETY.CAT.COM


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SEBU7600-12 125Maintenance Section

Maintenance Interval Schedule

i03512960

Maintenance Interval Schedule

SMCS Code: 7000

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

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

Use mileage, fuel consumption, service hours, or

calendar time, WHICH EVER OCCURS FIRST,in order to determine the maintenance intervals.Products that operate in severe operating conditionsmay require more frequent maintenance.

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

When Required

Axle Br eathers - Clean/Replace ......................... 127Battery - Recycle ................................................ 127Battery or Battery Cable - Inspect/Replace ........ 127

Boom Telescoping Cylinder Air - Purge .............. 134Boom and Frame - Inspect ................................. 137Circuit Breakers - Test ........................................ 140Circuit Breakers - Test ........................................ 141Cooling System Pressure Cap - Clean/Replace .. 148Engine Air Filter Primary Element - Clean/

Replace ............................................................. 154Engine Air Filter Secondary Element - Replace .. 157Fuel System - Prime ........................................... 166Fuel System - Prime ........................................... 167Fuel Tank Cap - Clean ........................................ 170Fuses and Relays - Replace ............................... 171Oil Filter - Inspect ................................................ 175Parking Brake - Adjust ........................................ 176

Radiator Core - Clean ......................................... 177Window Washer Reservoir - Fill .......................... 187Window Wiper - Inspect/Replace ........................ 187

Every 10 Service Hours or Daily

Backup Alarm - Test ............................................ 127Braking System - Test ......................................... 138Cooling System Coolant Level - Check .............. 146Engine Oil Level - Check .................................... 157Engine Oil Level - Check .................................... 158Fuel System Water Separator - Drain ................. 168Fuel System Water Separator - Drain ................. 169Fuel Tank Water and Sediment - Drain ............... 171

Indicators and Gauges - Test .............................. 174Seat Belt - Inspect .............................................. 179Tire Inflation - Check ........................................... 180Transmission and Hydraulic System Oil Level -

Check ................................................................ 184Wheel Nut Torque - Check .................................. 187

Windows - Clean . ................................................ 188Work Tool - Inspect/Replace ............................... 188

Every 50 Service Hours or Weekly

Pulley for Boom Extension Chain - Lubricate ..... 176Pulley for Boom Retraction Chain - Lubricate ..... 176

Every 100 Service Hours or Monthly

Longitudinal Stability Indicator - Test .................. 174

Every 250 Service Hours

Cooling System Coolant Sample (Level 1) -Obtain ............................................................... 147Engine Oil Sample - Obtain ................................ 159Engine Oil Sample - Obtain ................................ 159

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

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 148

Every 500 Service Hours

Differ ential Oil Sample - Obtain .......................... 153Final Drive Oil Sample - Obtain .......................... 165Transmission and Hydraulic System Oil Sample -

Obtain ............................................................... 185

Every 500 Service Hours or 6 Months

Boom Chain Tension - Check/Adjust .................. 129Boom Cylinder Pin - Lubricate ............................ 133Boom Head Section - Lubricate .......................... 133Boom Pivot Shaft - Lubricate .............................. 134Cab Air Filter - Clean/Replace ............................ 139Differential Oil Level - Check .............................. 152Drive Shaft Spline - Lubricate ............................. 153Engine Air Filter Primary Element - Clean/

Replace ............................................................. 154

Engine Air Filter Primary Element - Replace ...... 156Engine Air Filter Secondary Element - Replace .. 157Engine Oil and Filter - Change ........................... 160Engine Oil and Filter - Change ........................... 161Final Drive Oil Level - Check .............................. 164Fork Leveling Cylinder Pin - Lubricate ................ 165Fr ame Leveling Cylinder Pin - Lubricate ............. 166Fuel System Secondary Filter - Replace ............ 167Longitudinal Stability Indicator - Calibrate .......... 174Stabilizer and Cylinder Bearings - Lubricate ....... 180

Every 1000 Service Hours or 1 Year

Belt - Inspect/Replace ......................................... 128


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126 SEBU7600-12Maintenance SectionMaintenance Interval Schedule

Boom Wear Pad Clearance - Inspect/Adjust ...... 134Differential Oil - Change ..................................... 151Engine Valve Lash - Check ................................. 162Final Drive Oil - Change ..................................... 163Rollover Protective Structure (ROPS) and Falling

Object Protective Structure (FOPS) - Inspect ... 178

Transmission and Hydraulic System Oil -Change ............................................................. 181

Transmission and Hydraulic System Oil Filter -Replace ............................................................. 183

Work Tool - Inspect/Replace ............................... 188

Every 2000 Service Hours or 2 Years

Engine Valve Lash - Check ................................. 163Refrigerant Dryer - Replace ................................ 178Transmission and Hydraulic System Tank Breather -

Clean ................................................................. 186Transmission and Hydraulic System Tank Breather -

Clean ................................................................. 186

Turbocharger - Inspect ........................................ 187

Every Year

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 148

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

Seat Belt - Replace ............................................. 180


Boom Chain - Inspect/Lubricate ......................... 129Cooling System Water Temperature Regulator -Replace ............................................................. 149

Cooling System Water Temperature Regulator -Replace ............................................................. 150

Engine Mounts - Inspect ..................................... 157


Cooling System Coolant Extender (ELC) - Add .. 146

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 142Cooling System Coolant (ELC) - Change ........... 144


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Axle Breathers - Clean/Replace

i01953462

Axle Breathers - Clean/Replace

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

1. Park the machine on level ground. Fully retractthe boom and fully lower the boom. Move thetransmission control to the NEUTRAL position andensure that the parking brake is engaged. Shutoff the engine.

g01000311Illustration 174

Front axle breather


Rear axle breather

2. Clean the area around the breathers. Remove thebreathers from the front and rear axles.

3. Wash the breathers in clean nonflammablesolvent. Wipe the breathers dry and check thebreathers for damage.

4. Replace the breathers if the breathers aredamaged. Install the clean breathers back into theaxles.

i01565564

Backup Alarm - TestSMCS Code: 7406-081

The backup alarm is mounted at the rear of themachine.

Turn the engine start switch to the ON position inorder to perform the test.

Apply the service brake. Move the transmissioncontrol lever to the REVERSE position.

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

The backup alarm has one sound level. The soundlevel is not adjustable.

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

i01864907

Battery or Battery Cable -

Inspect/Replace

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

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


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128 SEBU7600-12Maintenance SectionBelt - Inspect/Replace

2. The battery disconnect switch (if equipped) islocated in the engine compartment above thebattery. Turn the key for the battery disconnectswitch to the OFF position. Remove the key. Refer to Operation and Maintenance Manual, “BatteryDisconnect Switch” for further information.

3. Disconnect the negative battery cable at thebattery disconnect switch.

Note: Some machines are equipped with twobatteries. Do not allow the disconnected batterycable to contact the battery disconnect switch or themachine.

4. Disconnect the negative battery cable from thebattery.

5. Disconnect the positive cable at the battery end.

6. Inspect the battery terminals for corrosion. Inspectthe battery cables for wear or damage.

7. If necessary, make repairs. If necessary, replacethe battery cables, the battery or the batterydisconnect switch.

8. Connect the positive cable at the battery end.

9. Connect the negative battery cable at the battery.

10. Connect the negative battery cable at the batterydisconnect switch.

11. Install the key for the battery disconnect switch.Turn the battery disconnect switch to the ONposition.

i02209940

Belt - Inspect/Replace

SMCS Code: 1397-040; 1397-510

Inspect

Note: If a new belt is installed, check the film on

the belt tensioner (2) after 30 minutes of operation. A belt is considered to be used after 30 minutes of operation.

1. Park the machine on level ground. Fully retractthe boom and fully lower the boom. Move thetransmission control to the NEUTRAL position andengage the parking brake. Shut off the engine.

2. Open the engine enclosure.


3. Inspect the condition of belt (1).

4. Replace the belt if any of the following conditionsexist:

• excessive cracking

• excessive wear

• excessive damage

5. Inspect the free arm stop of the belt tensioner (2).The free arm stop must be aligned with the blackline which is on the decal of belt tensioner (2). If the free arm stop is in the red area, replace thebelt.

6. Close the engine enclosure.

Replace

1. Park the machine on level ground. Fully retractthe boom and fully lower the boom. Move thetransmission control to the NEUTRAL position and

engage the parking brake. Shut off the engine.


3. Turn the battery disconnect switch to the OFFposition.

4. Remove the retaining bolts for the fan guard. Slidethe guard out of the engine enclosure.


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Boom Chain - Inspect/Lubricate


5. Release the tension on the belt (1). Insert a12.7 mm (0.50 inch) ratchet into the square holein the belt tensioner (2) and pry the belt tensioner in a clockwise direction.

6. Remove the belt from the pulleys. Feed the beltover the fan.

7. Install the new belt around the pulleys. Pry thebelt tensioner in a clockwise direction. Install thebelt around the belt tensioner. Release the belttensioner in order to put tension on the belt. Therouting of the belt is shown in Illustration 177.

8. Install the fan guard and tighten the retaining boltsto a torque of 15 ± 3 N·m (11.1 ± 2.2 lb ft).

9. Turn the battery disconnect switch to the ONposition.


i01881146

Boom Chain - Inspect/Lubricate

SMCS Code: 6460-040-CX; 6460-086-CX

Note: The information that follows will only relate tomachines that have a three-section boom.


The boom extension chain and boom retraction chainmust be removed from the boom for inspection. After removal, measure the chains for wear. Chains which

are serviceable must be lubricated before reinstallingthe chains. For the correct procedure, refer to theHydraulic System Systems Operation, Testing and

Adjusting, “Boom Chain - Clean/Inspect/Lubricate” or refer to your Caterpillar dealer for details.

i02408682

Boom Chain Tension -Check/Adjust

SMCS Code: 5917-025-BM; 5917-535-BM

S/N: SLD1-Up

S/N: SLE1-Up

S/N: JRK1-Up

You must read the warnings and instructionswhich are contained in the safety section of thismanual. Before you perform any operation or maintenance procedures ensure you understandthe warnings and instructions.

Check Condition

1. Park the machine on level ground. Fully retractthe boom and lower the boom.

2. Remove the cover from the rear of the chassis.


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130 SEBU7600-12Maintenance SectionBoom Chain Tension - Check/Adjust

3. A limited inspection of the chains can be madethrough the rear of the boom. The boom extensionchain can be inspected by fully extending theboom and looking on top of the intermediatesection. If the chains are corroded, the chainsmust be removed from the boom for cleaning and

a full inspection. If the chains require lubricant,the chains must be removed from the boomfor cleaning and a full inspection. Refer to theHydraulic System Systems Operation, Testing and

Adjusting, “Boom Chain - Clean/Inspect/Lubricate”or consult your Caterpillar dealer.

4. Install the cover on the rear of the boom.

Check and Adjust the ChainTension

1. Slacken the extension chain and the retraction

chain slightly. Raise the boom to the maximumangle and retract the boom. This ensures that allsections of the boom are fully retracted. If theretraction chain requires adjustment and the boomis retracted in a lowered position, all the sectionswill not fully retract.

The boom can fall if a control is moved or if a hy-draulic component fails. This can cause personalinjury or death. Support the boom with stands. Donot rely on the cylinder to hold the boom up.


2. Lower the boom to the horizontal position andinstall a suitable stand under the first sectionin order to prevent the boom from fallingunexpectedly. To properly support the boom, usethe following tools:

Table 18

Required Tools

Part Number Description Quantity

8S-7641 Tube 1

4C-6486 Stand 1

8S-7615 Pin 1

8S-7625 Collar 1

8S-8048 Saddle 1

3. Lower the boom to a position just above the standand stop the engine.



4. Set the minimum distance to 224 mm (8.8 inch)between boom section 2 and boom section 3. Themaximum allowable distance is 234 mm (9.2 inch).Tighten extension chain (1) in order to movesection 3 outward. Tighten retraction chain (2) inorder to move section 3 inward. If the distance issignificantly more than 224 mm (8.8 inch), slackenboth chains and refer to Step 1.

5. After setting the distance to the required tolerance,tighten the extension chain to 20 N·m (15 lb ft).

6. Tighten the retraction chain to 18 N·m (13 lb ft).


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Boom Chain Tension - Check/Adjust

7. Tighten the extension chain to 105 ± 5 N·m(77 ± 4 lb ft).

8. Tighten the retraction chain to 70 ± 5 N·m(52 ± 4 lb ft).

9. Extend the boom and retract the boom severaltimes. Check the torque for the extension chain.Check the torque for the retraction chain.

10. Install the locknut for the extension chain. Torquethe locknut for the extension chain to 105 ± 5 N·m(77 ± 4 lb ft).

11. Install the locknut for the retraction chain. Torquethe locknut for the retraction chain to 70 ± 5 N·m(52 ± 4 lb ft).

12. Check the shackles on both chains. If necessary,adjust the shackles in order to set the shackles

horizontally.

13. Remove the stand and lower the boom.

Measure the Chain for Wear

Nominal pitch of the link equals 25.4 mm (1 inch).

Nominal height of the plate equals 24.1 mm(0.95 inch).

1. Fully retract the boom. Position the boomhorizontally.

2. Extend the boom by 2 m (6 ft 7 inch) or extend theboom to the section of chain that most frequentlypasses over the boom extension chain pulley.

Do not retract the boom sections before youbegin to measure the chains.


3. Use a caliper in order to measure the height of inner plate (A) and the height of outer plate (A)over 15 pitches of the selected worn section of chain. If any inner plate or any outer plate showsa reduction in height of more than 5% wear, allchains must be replaced. Also, if the measurement

is less than 22.89 mm (0.901 inch), all chainsmust be replaced.

4. Use a 6V-0028 Wear Gauge As (CHAIN) in order to measure the chain between the 16 pin centersof the selected worn section (B). The nominallength of 16 pin centers is 381 mm (15 inch). If the measurement shows an elongation of morethat 2%, all chains must be replaced. Also, if the measur ement is greater than 388.6 mm(15.30 inch), all chains must be replaced.

i02408769

Boom Chain Tension -Check/Adjust

SMCS Code: 5917-025-BM; 5917-535-BM

S/N: SLF1-Up

You must read the warnings and instructionswhich are contained in the safety section of thismanual. Before you perform any operation or maintenance procedures ensure you understandthe warnings and instructions.

Check Condition

1. Park the machine on level ground. Fully retractthe boom and lower the boom.

2. Remove the cover from the rear of the chassis.

3. A limited inspection of the chains can be madethrough the rear of the boom. The boom extensionchain can be inspected by fully extending theboom and looking on top of the intermediatesection. If the chains are corroded, the chainsmust be removed from the boom for cleaning anda full inspection. If the chains require lubricant,the chains must be removed from the boomfor cleaning and a full inspection. Refer to theHydraulic System Systems Operation, Testing and

Adjusting, “Boom Chain - Clean/Inspect/Lubricate”or consult your Caterpillar dealer.

4. Install the cover on the rear of the boom.


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132 SEBU7600-12Maintenance SectionBoom Chain Tension - Check/Adjust

Check and Adjust the ChainTension

1. Slacken the extension chain and the retractionchain slightly. Raise the boom to the maximumangle and retract the boom. This ensures that allsections of the boom are fully retracted. If theretraction chain requires adjustment and the boomis retracted in a lowered position, all the sectionswill not fully retract.



2. Lower the boom to the horizontal position andinstall a suitable stand under the first sectionin order to prevent the boom from fallingunexpectedly. To properly support the boom, usethe following tools:

Table 19

Required Tools


8S-7641 Tube 1

4C-6486 Stand 1

8S-7615 Pin 1

8S-7625 Collar 1

8S-8048 Saddle 1

3. Lower the boom to a position just above the standand stop the engine.



4. Set the minimum distance to 212 mm (8.3 inch)

between boom section 2 and boom section 3. Themaximum allowable distance is 222 mm (8.7 inch).Tighten extension chain (1) in order to movesection 3 outward. Tighten retraction chain (2) inorder to move section 3 inward. If the distance issignificantly more than 212 mm (8.3 inch), slackenboth chains and refer to Step 1.

5. After setting the distance to the required tolerance,tighten the extension chain to 25 N·m (18 lb ft).

6. Tighten the retraction chain to 22 N·m (16 lb ft).

7. Tighten the extension chain to 130 ± 5 N·m

(96 ± 4 lb ft).

8. Tighten the retraction chain to 85 ± 5 N·m(63 ± 4 lb ft).

9. Extend the boom and retract the boom severaltimes. Check the torque for the extension chain.Check the torque for the retraction chain.

10. Install the locknut for the extension chain. Torquethe locknut for the extension chain to 130 ± 5 N·m(96 ± 4 lb ft).


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Boom Cylinder Pin - Lubricate

11. Install the locknut for the retraction chain. Torquethe locknut for the retraction chain to 85 ± 5 N·m(63 ± 4 lb ft).

12. Check the shackles on both chains. If necessary,adjust the shackles in order to set the shackles

horizontally.

13. Remove the stand and lower the boom.

Measure the Chain for Wear

Nominal pitch of the link equals 25.4 mm (1 inch).

Nominal height of the plate equals 24.1 mm(0.95 inch).

1. Fully retr act the boom. Position the boomhorizontally.

2. Extend the boom by 2 m (6 ft 7 inch) or extend theboom to the section of chain that most frequentlypasses over the boom extension chain pulley.

Do not retract the boom sections before youbegin to measure the chains.


3. Use a caliper in order to measure the height of inner plate (A) and the height of outer plate (A)over 15 pitches of the selected worn section of chain. If any inner plates or any outer plates show

a reduction in height of more than 5% wear, allchains must be replaced. Also, if the measurementis less than 22.89 mm (0.901 inch), all chainsmust be replaced.

4. Use a 6V-0028 Wear Gauge As (CHAIN) in order to measure the chain between the 16 pin centersof the selected worn section (B). The nominallength of 16 pin centers is 381 mm (15 inch). If the measurement shows an elongation of morethat 2%, all chains must be replaced. Also, if the measurement is greater than 388.6 mm(15.30 inch), all chains must be replaced.

i01867607

Boom Cylinder Pin - Lubricate

SMCS Code: 5456-086-PN


There is a boom raise cylinder under the boom.Lubricate the boom cylinder pin through the fitting atthe rod end of the cylinder.

i01925273

Boom Head Section - Lubricate

SMCS Code: 6501-086


Lubricate the boom head through the lubricationfitting.


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134 SEBU7600-12Maintenance SectionBoom Pivot Shaft - Lubricate

i01865009

Boom Pivot Shaft - Lubricate

SMCS Code: 6501-086-JF


Location of the pivot shaft for the boom


Lubricate the pivot shaft for the boom through thelubrication fitting. The lubrication fitting is located ontop of the pivot shaft for the boom.

i01618057

Boom Telescoping Cylinder Air - Purge

SMCS Code: 5486-542-AI

It may be necessary to purge air from the boomextend cylinder after the hydraulic oil has beenchanged. It may also be necessary to purge air fromthe boom extend cylinder after any disassembly of hydraulic system components.

Normally, the hydraulic system will purge air from theboom extend cylinder but air can be trapped. Air inboom extend cylinder can cause erratic boom motion.

1. If necessary, warm the hydraulic oil by raising theboom and lowering the boom.


2. Retract and lower the boom. Position the machine

on a down slope. Engage the parking brake.

3. Fully extend the boom and retract the boom sixtimes. This will purge air from the cylinders.

4. Move the machine back to level ground and checkthe operation of the boom motion.

i02599023

Boom Wear Pad Clearance -Inspect/Adjust

SMCS Code: 6460-025-JP; 6460-040-JP

The clearance between the wear pads and the boomsection should be checked at more frequent intervalswhen the machine is operated in severe conditions.

Note: Sand or grit particles can cause acceleratedwear to the wear pads.

1. Park the machine in a clear area on level groundand chock the wheels.



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Boom Wear Pad Clearance - Inspect/Adjust


2. Raise the boom to the horizontal position and fullyextend the boom. Install a suitable stand under the first section in order to prevent the boom

from falling unexpectedly. Do not support thesecond and third sections. To properly supportthe boom, use the following tools:

Table 20

Required Tools


8S-7641 Tube 1

4C-6486 Stand 1

8S-7615 Pin 1

8S-7625 Collar 1

8S-8048 Saddle 1

3. Stop the engine.


4. Measure clearances (1) between the wear padsand the side of the boom sections at each side.

5. Measure clearances (2) between the wear padsand the top of the boom sections.


6. Raise the boom and remove the stand. Fullyretract the boom and support the boom in thehorizontal position. In order to support the boom,

install the stand under the third section or installcribbing under the quick coupler.


7. Remove the cover from the rear of the chassisand measure clearances (3) between the rear wear pads and the side of the boom sections ateach side.

8. Measure clearances (4) between the rear wear pads and the top of the boom sections.

9. The clearance at each location must not exceed

1.5 mm (0.06 inch). If the clearances areexcessive, adjustments must be made.

Adjustment

Note: The bolts that secure different wear pads arenot identical lengths. Do not mix the bolts. Cleanall used bolts. Before installation, apply thread lockcompound to bolts that secure wear pads.


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136 SEBU7600-12Maintenance SectionBoom Wear Pad Clearance - Inspect/Adjust


1. Loosen bolts (5) that secure the rear top wear pads. Install suf ficient shims in order to reducethe clearance to 0.75 mm (0.030 inch). Apply

9S-3263 Thread Lock Compound to the bolts.Tighten the bolts to a torque of 60 ± 5 N·m(44 ± 4 lb ft).

2. Remove bolts (6) that secure the rear side wear pads. Install suf ficient shims in order to reduce theclearance to 0.75 mm (0.030 inch) at each side.Install suf ficient shims in order to produce an equalclearance between the boom sections at eachside. It may be necessary to install more shimsat one side than the other side. Apply 9S-3263Thread Lock Compound to the bolts. Tighten thebolts to a torque of 60 ± 5 N·m (44 ± 4 lb ft).


3. Raise the boom suf ficiently above the stand.Fully extend the boom and lower the boom to thehorizontal position. Support the boom under thethird section.


4. Remove bolts (7) that secure the bottom wear pads. Install suf ficient shims in order to reducethe clearance to 0.75 mm (0.030 inch). Apply

9S-3263 Thread Lock Compound to the bolts.Tighten the bolts to a torque of 60 ± 5 N·m(44 ± 4 lb ft).


5. Remove bolts (8) that secure the side wear pads.Install suf ficient shims in order to reduce theclearance to 0.75 mm (0.030 inch) at each side.Install suf ficient shims in order to produce an equalclearance between the wear pads and the boomsections at each side. It may be necessary toinstall more shims at one side than the other side.

Apply 9S-3263 Thread Lock Compound to the

bolts. Tighten the bolts to a torque of 60 ± 5 N·m(44 ± 4 lb ft).

6. Fully extend and retract the boom at angles of 0degrees, 45 degrees and 70 degrees. The boomoperation must be smooth. If the boom operationis not smooth, operate the boom with a load of 500 kg (1100 lb) on the attachment. Fully extendthe boom and retract the boom at an angle of 45degrees. Repeat ten times.


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138 SEBU7600-12Maintenance SectionBraking System - Test

• Towing attachment (if equipped)

• Mountings on the frame

• Stabilizers (if equipped)

• Tie down lugs


Stabilizer and rollover protection structure

Lower stabilizers (2) until the stabilizer pads aretouching the ground. Inspect each stabilizer fully.Inspect the beams, stabilizer pads, mountinghardware, cylinders and the pivot pins.

If equipped, inspect Rollover Protection Structure(ROPS) (3) or inspect Falling Objects ProtectionStructure (FOPS) (3). Inspect the ROPS or the FOPScarefully. Do not attempt to straighten the structure.

Do not attempt to repair the structure by welding.Consult your Caterpillar dealer if damage is found tothe ROPS or to the FOPS.


Boom and quick coupler

Inspect all sections of boom (4). Inspect the boomafter the boom is extended fully and the work tool ison the ground.

Completely inspect quick coupler (5). Also, inspectthe work tool.


Pivot pins and anchor points

Inspect all pivot pins and inspect all anchor pointsfor wear.

i02294939

Braking System - Test

SMCS Code: 4250-081

Service Brake

Check the area around the machine. Make sure thatthe area is clear of personnel and obstacles.

Check the brakes on a dry, level surface.

Fasten the seat belt before you check the brakes.

The following procedure is used in order to determineif the service brake is functional. This procedureis not intended to measure the maximum brakeperformance. The brake holding torque that isrequired to sustain an engine torque at a specificengine rpm varies depending on the machineconfiguration. The variations are the differences inthe engine setting, in the power train ef ficiency, andin the brake holding ability, etc.

Test Procedure

1. Remove the work tool and park the machine inthe travel position.

2. Start the engine and disengage the parkingbrake. Place the transmission in FIRST GEARFORWARD.

3. Apply the service brake and fully depress theaccelerator pedal in order to increase the enginespeed.

4. The machine should remain stationary during thistest.


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Cab Air Filter - Clean/Replace

5. Switch off the engine and engage the parkingbrake.

If the machine moved while testing the servicebrakes, contact your Caterpillar dealer.

Have the dealer inspect, and if necessary repair the service brakes before returning the machineto operation. Failure to have the service brakesinspected and repaired can cause injury or death.

Reference: See Systems Operation, Testing and Adjusting, RENR5190, “TH220B, TH330B, TH340B,TH350B, 355B, TH360B, TH460B, TH560B andTH580B Telehanders Braking System”, “ServiceBrake Control - Check and Adjust” for moreinformation.

Parking Brake

Check the area around the machine. Make sure thatthe area is clear of personnel and obstacles.

Check the brakes on a dry, level surface.

Fasten the seat belt before you check the brakes.

The following procedure is used in order to determineif the parking brake is functional. This procedureis not intended to measure the maximum brake

performance. The brake holding torque that isrequired to sustain an engine torque at a specificengine rpm varies depending on the machineconfiguration. The variations are the differences inthe engine setting, in the power train ef ficiency, andin the brake holding ability, etc.

Test Procedure

1. Start the engine.

2. Engage the parking brake.

3. If the machine is equipped with a standard

transmission, move the transmission control lever in the following pattern:

• SECOND

• NEUTRAL

• SECOND

This is done in order to override the transmissionneutralizer for this test.

Note: The indicator light for the parking brake shouldcome on.

4. If the machine is equipped with a power shifttransmission, move the transmission control lever in the following pattern:

• SECOND GEAR FORWARD

• NEUTRAL

• SECOND GEAR FORWARD

This is done in order to override the transmissionneutralizer for this test.

Note: The indicator light for the parking brake shouldcome on.

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

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

6. Reduce the engine speed. Move the transmissioncontrol lever to NEUTRAL.

If the machine moved during the test, performthe maintenance procedure Operation andMaintenance Manual, “Parking Brake - Adjust”.

i02412631

Cab Air Filter - Clean/Replace

SMCS Code: 7342-070; 7342-510

There are two cab air filters.


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140 SEBU7600-12Maintenance SectionCircuit Breakers - Test

Primary Cab Air Filter


1. The primary cab air filter is located behindprotection cover (3) on the left side of the cab. Inorder to open the protection cover, unlock lock(2) and turn lock (4) counterclockwise. Then, pulllatch (1) outward.


2. Open fi lter cover (6) by removing retaining screw

(5).

3. Remove the filter from behind fi lter cover (6).

4. If the air filter is not damaged, clean the air filter with pressurized air. The maximum air pressurefor cleaning is 205 kPa (30 psi).

Direct pressurized air along the pleats from nocloser than 160 mm (6 inch) from the air fi lter.

If the air filter is damaged, replace the air filter.

Secondary Cab Air Filter

The secondary cab air filter is located inside the cab.The filter is on the rear wall of the cab behind the seat.


1. Open fi lter cover (7) by removing retaining screws(8).

2. Remove the fi lter from the filter housing.

3. If the air fi lter is not damaged, clean the air fi lter with pr essurized air. The maximum air pressurefor cleaning is 205 kPa (30 psi).

Direct pressurized air along the pleats from nocloser than 160 mm (6 inch) from the air fi lter.

If the air fi lter is damaged, replace the air fi lter.

i01949818

Circuit Breakers - Test

SMCS Code: 1420-081

S/N: SLD1-531

S/N: SLE1-1250

S/N: SLF1-791

The circuit breakers for the alternator and for the

battery are located under the engine hood on thefront right side of the engine compartment.


19/68


20/68

142 SEBU7600-12Maintenance SectionCooling System Coolant (ELC) - Change

i02429540

Cooling System Coolant (ELC)- Change

SMCS Code: 1395-044-NL

S/N: SLD1-531

S/N: SLE1-1250

S/N: SLF1-791

Personal injury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all lines

to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.

Remove filler cap slowly to relieve pressure onlywhen engine is stopped and radiator cap is coolenough to touch with your bare hand.

Do not attempt to tighten hose connections whenthe coolant is hot, the hose can come off causingburns.

Cooling System Conditioner contains alkali. Avoidcontact with skin and eyes.

NOTICEDo not change the coolant until you read and under-stand the material found in the Special Publication,SEBU6250, “Caterpillar Machine Fluids Recommen-dations”. Failure to do so could result in damage tothe cooling systems components.

NOTICEMixing ELC with other products reduces the effective-ness of the coolant and shortens coolant life. Use onlyCaterpillar products or commercial products that havepassed the Caterpillar EC-1 specifications for pre-

mixed or concentrate coolants. Use only Caterpillar Extender with Caterpillar ELC. Failure to follow theserecommendations could result in the damage to cool-ing systems components.

If ELC cooling system contamination occurs see thetopic Extended Life Coolant (ELC) in the Special Pub-lication, SEBU6250, “Caterpillar Machine Fluids Rec-ommendations”.

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

ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations andmandates.

If the coolant in the machine is changed fromextended life coolant to another type of coolant,

consult your Caterpillar dealer.

1. Allow the engine to cool.


2. Loosen pressure cap (1) from the coolant tankslowly in order to release pressure. Remove thepressure cap.



21/68


22/68

144 SEBU7600-12Maintenance SectionCooling System Coolant (ELC) - Change

14. Inspect the gasket of the pressure cap. If thegasket is damaged, replace the cap.

15. Install the pr essure cap on the coolant tank.

16. Stop the engine.

i02429541

Cooling System Coolant (ELC)- Change


S/N: SLD600-Up

S/N: SLE1350-Up

S/N: SLF900-Up

S/N: JRK1-Up


At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.

Remove filler cap slowly to relieve pressure only

when engine is stopped and radiator cap is coolenough to touch with your bare hand.



NOTICEDo not change the coolant until you read and under-stand the material found in the Special Publication,SEBU6250, “Caterpillar Machine Fluids Recommen-dations”. Failure to do so could result in damage tothe cooling systems components.

NOTICEMixing ELC with other products reduces the effective-ness of the coolant and shortens coolant life. Use onlyCaterpillar products or commercial products that havepassed the Caterpillar EC-1 specifications for pre-

mixed or concentrate coolants. Use only Caterpillar Extender with Caterpillar ELC. Failure to follow theserecommendations could result in the damage to cool-ing systems components.

If ELC cooling system contamination occurs see thetopic Extended Life Coolant (ELC) in the Special Pub-lication, SEBU6250, “Caterpillar Machine Fluids Rec-ommendations”.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-

ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.



If the coolant in the machine is changed fromextended life coolant to another type of coolant,consult your Caterpillar dealer.

1. Allow the engine to cool.


2. Loosen pressure cap (1) from the coolant tankslowly in order to release pressure. Remove thepressure cap.


23/68


Cooling System Coolant (ELC) - Change


3. Loosen drain valve (2) that is located at the bottomright corner of the radiator. Drain the coolant into asuitable container.


4. Remove coolant drain plug (3) that is locatedin the engine block above the starter. Drain thecoolant into a suitable container.

Note: Check the threads of the drain plug for damage. Check the sealant on the drain plug for damage. The drain plug can be reused if threads arenot damaged and the sealant is not damaged.


5. Loosen hose clamp (5) that is located on thehydraulic oil cooler. Remove hose (4). Allow thecoolant to drain into a suitable container.


6. If the machine is equipped with a cab heater,turn the heater control that is located inside thecab to the HOT position. Loosen hose clamp (6).Remove hose (7). Allow the coolant to drain into asuitable container.

7. Flush the cooling system with clean water until thedraining water is transparent.

8. Close drain valve (2).

9. Reinstall coolant drain plug (3) in the engine blockabove the starter. Tighten the plug.

10. Reinstall hoses (4) and (7). Tighten clamps (5)and (6).

NOTICEAdd the coolant solution at a maximum rate of fiveliters per minute. This will reduce the chance of trap-ping air inside the engine block. A large amount of trapped air can cause localized heating to occur uponstart-up. Localized heating may result in engine dam-age, which may lead to failure of the engine.

11. Add the Extended Life Coolant into the coolanttank. Refer to the following topics:

• Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations”, “CoolingSystem Specifications”

• Operation and Maintenance Manual, “Capacities(Refill)”

12. Start the engine. Operate the engine without thepressure cap for the coolant tank until the coolanttemperature regulator opens and the coolant levelstabilizes.


24/68

146 SEBU7600-12Maintenance SectionCooling System Coolant Extender (ELC) - Add

13. Maintain the coolant level up to the FULL markon the coolant tank.

14. Inspect the gasket of the pressure cap. If thegasket is damaged, replace the cap.

15. Install the pressure cap on the coolant tank.

16. Stop the engine.

i01662174

Cooling System CoolantExtender (ELC) - Add





Do not attempt to tighten hose connections when

the coolant is hot, the hose can come off causingburns.


When a Caterpillar Extended Life Coolant (ELC)is used, an extender must be added to the coolingsystem. Refer to the Operation and MaintenanceManual, “Maintenance Interval Schedule” for theproper service interval. The amount of extender isdetermined by the cooling system capacity.

Table 22

Caterpillar Extender (ELC)

Cooling System Capacity Recommended Amountof Caterpillar Extender

22 to 30 L (6 to 8 US gal) 0.57 L (20 oz)

30 to 38 L (8 to 10 US gal) 0.71 L (24 oz)

38 to 49 L (10 to 13 US gal) 0.95 L (32 oz)

49 to 64 L (13 to 17 US gal) 1.18 L (40 oz)

64 to 83 L (17 to 22 US gal) 1.60 L (54 oz)

83 to 114 L (22 to 30 US gal) 2.15 L (72 oz)

114 to 163 L (30 to 43 US gal) 3.00 L (100 oz)

163 to 242 L (43 to 64 US gal) 4.40 L (148 oz)

For additional information about adding an extender,consult your Caterpillar Dealer.

i02063615

Cooling System Coolant Level- Check

SMCS Code: 1350-535-FLV






Park the machine on level ground. Fully retractthe boom and fully lower the boom. Move thetransmission control to the NEUTRAL position andensure that the parking brake is engaged. Shut off the engine.


25/68


Cooling System Coolant Sample (Level 1) - Obtain


The coolant tank for the cooling system is located inthe engine compartment.

Check the coolant level while the engine is cold. Thecoolant level should be maintained to the “FULL” lineon the coolant tank.

i02253552

Cooling System CoolantSample (Level 1) - Obtain

SMCS Code: 1395-008; 7542

Note: It is not necessary to obtain a CoolantSample (Level 1) if the cooling system is filled

with Cat ELC (Extended Life Coolant). Coolingsystems that are filled with Cat ELC should havea Coolant Sample (Level 2) that is obtained atthe recommended interval that is stated in theMaintenance Interval Schedule.

Note: Obtain a Coolant Sample (Level 1) if thecooling system is filled with any other coolantinstead of Cat ELC. This includes the followingtypes of coolants.

• Commercial long life coolants that meet theCaterpillar Engine Coolant Specification -1(Caterpillar EC-1)

• Cat Diesel Engine Antifreeze/Coolant (DEAC)

• Commercial heavy-duty coolant/antifreeze

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

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


Refer to the Operation and Maintenance Manual,

“Access Doors and Covers” for the location of theservice points.

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In order to receive the full effect of S·O·S analysis, youmust establish a consistent trend of data. In order to 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 of the 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.


26/68

148 SEBU7600-12Maintenance SectionCooling System Coolant Sample (Level 2) - Obtain

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

i02124459

Cooling System CoolantSample (Level 2) - Obtain

SMCS Code: 1395-008; 7542

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


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

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

i02124461

Cooling System Pressure Cap- Clean/Replace

SMCS Code: 1382-070; 1382-510



Remove filler cap slowly to relieve pressure onlywhen engine is stopped and radiator cap is cool

enough to touch with your bare hand.




The cooling system pressure cap is located on thecoolant tank inside the engine compartment.

1. Remove the cap slowly in order to relieve thepressure.

2. Inspect the cap and the gasket for damage, for foreign material, and for deposits.

3. Clean the cap with a clean cloth or replace thecap if it is necessary.

Note: Always check the pressure rating of the oldcap before you replace the cap. Replace the old capwith a new cap of the same pressure rating.


27/68


Cooling System Water Temperature Regulator - Replace

4. Reinstall the cap.

i02429542

Cooling System Water

Temperatur e Regulator -Replace

SMCS Code: 1355-510; 1393-010

S/N: SLD1-531

S/N: SLE1-1250

S/N: SLF1-791

Personal injury can result from hot coolant, steam

and alkali.





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

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillar products.


The water temperature regulator is located on the topof the engine.

Replace the water temperature regulator on a regular basis in order to reduce the chance of unscheduleddowntime and of problems with the cooling system.The water temperature regulator should also bereplaced after the cooling system has been cleaned.

Replace the water temperature regulator while thecooling system is completely drained or while thecooling system coolant is drained to a level that isbelow the water temperature regulator housing.

NOTICEFailure to replace the engine's water temperature reg-ulator on a regularly scheduled basis could cause se-vere engine damage.

Note: If you are only replacing the water temperatureregulator, drain the cooling system coolant to alevel that is below the water temperature regulator

housing.


1. Loosen hose clamp (1).

2. Remove hose (2) from the housing.


4. Remove hose (4) from the fitting.

5. Remove bolts and washers (5).

6. Remove water temperature regulator housing (6).Remove the water temperature regulator and thegasket.

NOTICEIf the water temperature regulator is installed incor-rectly, it will cause the engine to overheat.

7. Install a new water temperature regulator and anew gasket.

8. Install water temperature regulator housing (6).


28/68

150 SEBU7600-12Maintenance SectionCooling System Water Temperature Regulator - Replace

9. Install washer s and bolts (5). Tighten the bolts.

10. Install hose (4). Tighten hose clamp (3).


12. Refill the cooling system. Refer to Operationand Maintenance Manual, “Capacities (Refill)”and Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations”.

i02429544

Cooling System Water Temperature Regulator -Replace

SMCS Code: 1355-510; 1393-010

S/N: SLD600-Up

S/N: SLE1350-Up

S/N: SLF900-Up

S/N: JRK1-Up


At operating temperature, engine coolant is hot

and under pressure. The radiator and all linesto heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.








NOTICEFailure to replace the engine's water temperature reg-

ulator on a regularly scheduled basis could cause se-vere engine damage.

NOTICESince Caterpillar engines incorporate a shunt designcooling system, it is mandatory to always operate theengine with a water temperature regulator.

Depending on load, failure to operate with a water temperature regulator could result in either an over-heating or an overcooling condition.

Replace the water temperature regulator on a regular basis in order to reduce the chance of unscheduleddowntime and of problems with the cooling system.The water temperature regulator should also bereplaced after the cooling system has been cleaned.

Replace the water temperature regulator while thecooling system is completely drained or while thecooling system coolant is drained to a level that isbelow the water temperature regulator housing.




29/68


Differential Oil - Change

2. Remove hose (2) from the housing.


4. Remove hose (4) from the fitting.

5. Remove bolts and washers (5).

6. Remove water temperature regulator housing (6).Remove the water temperature regulator and thegasket.

NOTICEIf the water temperature regulator is installed incor-rectly, it will cause the engine to overheat.

7. Install a new water temperature regulator and anew gasket.

8. Install water temperature regulator housing (6).

9. Install washers and bolts (5). Tighten the bolts.



12. Refill the cooling system. Refer to Operationand Maintenance Manual, “Capacities (Refill)”and Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations”.

i02429545

Differential Oil - Change

SMCS Code: 3258-044-OC


Ref er to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillar pr oducts.


Park the machine on level ground. Fully retractthe boom and fully lower the boom. Move thetransmission control to the NEUTRAL position andengage the parking brake. Shut off the engine.

Rear Axle Differential


1. Clean the area around the plugs. Remove thefollowing plugs for the rear differential:

• Drain plug (1)

• Combined level plug and filler plug (2)

Allow the oil to drain into a suitable container.

2. Clean drain plug (1) and reinstall drain plug (1).

3. Add new oil to the differential housing throughfiller hole (2) until the oil is level with the threadsfor plug (2). Refer to Operator and MaintenanceManual, “Lubricant Viscosities” for the correctgrade of oil. Refer to Operation and Maintenance

Manual, “Capacities (Refill)” and SpecialPublication, SEBU6250, “Caterpillar MachineFluids Recommendations” for more detailedlubricant information.

4. Clean combined level plug and filler plug (2).Reinstall combined level plug and fi ller plug (2).

Front Axle Differential


1. Clean the area around the plugs. Remove thefollowing plugs for the front differential:


30/68

152 SEBU7600-12Maintenance SectionDifferential Oil Level - Check

• Drain plug (3)

• Combined level plug and filler plug (4)

Allow the oil to drain into a suitable container.

2. Clean drain plug (3) and reinstall drain plug (3).

3. Add new 197-0017 Axle and Brake Oil Additive tothe differential housing through hole (4). Refer toOperation and Maintenance Manual, “Capacities(Refill)” for more detailed information.

4. Add new oil to the differential housing through filler hole (4) until the oil is level with the threads for plug (4). When you are fi lling the front axle with oilyou should allow time for the oil to drain throughthe differential into the other side of the axle.Ensure that the correct quantity of oil is added tothe axle in order to fill the differential and the axle

housing. Damage to the differential will result if this procedure is not observed. Refer to Operator and Maintenance Manual, “Lubricant Viscosities”for the correct grade of oil.

Refer to Operation and Maintenance Manual,“Capacities (Refill)” and Special Publication,SEBU6250, “Caterpillar Machine FluidsRecommendations” for more detailed lubricantinformation.

5. Clean combined level plug and filler plug (4).Reinstall combined level plug and fi ller plug (4).

i02429547

Differential Oil Level - Check





Park the machine on level ground. Fully retractthe boom and fully lower the boom. Move thetransmission control to the NEUTRAL position andengage the parking brake. Shut off the engine.

Rear Axle Differential


1. Clean the area around combined level and filler plug (1) f or the rear differential. Remove combined

level and fi ller plug (1) and check that the oil islevel with the hole for combined level and filler plug (1).

2. If necessary, add oil through the same hole.

3. Clean combined level and fi ller plug (1) and installcombined level and fi ller plug (1).

Front Axle Differential


1. Clean the area around combined level and

filler plug (2) for the front differential. Removecombined level and fi ller plug (2) and check thatthe oil is level with the hole.

2. If necessary, add oil through the same hole.

3. Clean combined level and fi ller plug (2) and installcombined level and fi ller plug (2).


31/68


Differential Oil Sample - Obtain

i02429548

Differential Oil Sample - Obtain

SMCS Code: 3258-008

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contactskin.






Rear axle differential


Front axle differential

Obtain a sample of oil from each axle. Keep the oilsamples separate from each other.

Clean the area around filler plug (1) for the differential.Remove the filler plug. Use a sampling gun in thefiller hole in order to obtain an oil sample from thedifferential. Inspect the fi ller plug for damage. Installthe filler plug.

Analysis of oil from each axle will provide an accuraterepresentation of oil condition within each system.

Use S·O·S Oil Analysis in order to monitor thecondition of your oil.

For additional information, refer to Special

Publication, SEBU6250, “Caterpillar Machine FluidsRecommendations”.

i01618061

Drive Shaft Spline - Lubricate

SMCS Code: 3253-086-SN

NOTICE Apply lubricant to the fittings with a hand operatedgrease gun only. Use of pressure operated lubricatingequipment damages the seals.


32/68

154 SEBU7600-12Maintenance SectionEngine Air Filter Primary Element - Clean/Replace


Location of the Drive Shafts

The following drive shafts must be lubricated:

• The front drive shaft

• The rear drive shaft


Typical Lubrication Point

Ther e is a grease nipple on the slider of each driveshaft.

Lubricate the drive shaft splines through the greasenipples.

i02063533

Engine Air Filter PrimaryElement - Clean/Replace

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

Note: The primary air fi lter element can be used upto three times if the element is properly cleaned andinspected. Replace the primary air filter element if the element has been in service for 500 hours or six months. This replacement should be performedregardless of the number of cleanings.



2. Slide out retaining clip (1).

3. Release cover (2) from air filter housing (3) byrotating counterclockwise. Remove the cover fromthe housing.

4. Remove primary element (4) from filter housing(3). To avoid dislodging any dust, take care toavoid touching the element against the sides of the housing. Inspect the primary element. If thepleats or the seals are damaged, discard theprimary element. Replace a damaged primaryelement with a clean primary element.

5. If the primary element is not damaged, you may

clean the primary element. Refer to Operation andMaintenance Manual, “Cleaning Primary Air Filter Elements”.

6. When you clean the inside of the pleats, direct theair along the pleats. Inspect the primary elementafter you clean the primary element.

7. Clean the inside of the filter housing and cleanthe cover. Pay particular attention to the sealingsurface of the outlet tube, which fits inside theprimary element.

8. Install a clean primary element.

9. Install the cover.

10. Reset the engine air filter service indicator bypressing button (5).


33/68


Engine Air Filter Primary Element - Clean/Replace


11. Start the engine. If the engine air filter serviceindicator (6) illuminates on the dash panel,install a new primary element. Refer to the

“Alert Indicators” section of Operation andMaintenance Manual, “Monitoring System” for further information. Also, if the exhaust smokeis black, install a new primary element. Replacethe engine air filter secondary element when youreplace the primary filter element. Refer to theOperation and Maintenance Manual, “Engine Air Filter Secondary Element - Replace”.


Cleaning Primary Air Filter Elements

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

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

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

Do not wash the fi lter element.

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

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

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

damage could result.

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

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

• Pressurized air

• Vacuum cleaning

Pressurized Air

Pressurized air can be used to clean primary air filter elements that have not been cleaned more than twotimes. Pressurized air will not remove deposits of carbon and oil. Use fi ltered, dry air with a maximumpressur e of 207 kPa (30 psi).


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

(outside).

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


34/68

156 SEBU7600-12Maintenance SectionEngine Air Filter Primary Element - Replace

Vacuum Cleaning

Vacuum cleaning is another method for cleaningprimary air filter elements which require daily cleaningbecause of a dry, dusty environment. Cleaning withpressurized air is recommended prior to vacuum

cleaning. Vacuum cleaning will not remove depositsof carbon and oil.

Inspecting the Primary Air Filter Elements


Inspect the clean, dry primary air filter element. Usea 60 watt blue light in a dark room or in a similar facility. Place the blue light in the primary air filter element. Rotate the primary air fi lter element. Inspectthe primary air filter element for tears and/or holes.

Inspect the primary air filter element for light that mayshow through the fi lter material. If it is necessary inorder to confirm the result, compare the primary air filter element to a new primary air fi lter element thathas the same part number.

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

Storing Primary Air Filter Elements

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


Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. An air flow restrictionmay result. To protect against dirt and damage, wrap

the primary air filter elements in Volatile CorrosionInhibited (VCI) paper.

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

• Date of cleaning

• Number of cleanings

Store the box in a dry location.

i02124504

Engine Air Filter PrimaryElement - Replace

SMCS Code: 1054-510-PY

NOTICEThe filter should be kept in service no longer than sixmonths or 500 service hours.

Refer to Operation and Maintenance Manual, “Engine

Air Filter Primary Element - Clean/Replace” for thereplacement procedure.

Write the date on the element, when the element isreplaced.


35/68


36/68

158 SEBU7600-12Maintenance SectionEngine Oil Level - Check


1. Open the engine enclosure. Oil level dipstick (1) islocated on the front of the engine.

2. Maintain the oil level between the “ADD” mark andthe “FULL” mark on the dipstick.

Note: When you operate the machine on severeslopes, the oil level in the engine crankcase must beat the “FULL” mark on the dipstick.

3. Clean oil filler cap (2) . Remove fi ller cap (2). If necessary, add oil.

4. Install filler cap (2).


i02124465

Engine Oil Level - Check


S/N: SLD600-Up

S/N: SLE1350-Up

S/N: SLF900-Up

S/N: JRK1-Up

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact skin.

NOTICEDo not under fill or over fill engine crankcase with oil.Either condition can cause engine damage.

Park the machine on level ground.

Check the crankcase oil level with the machine level.If the machine has just been stopped, wait for aminimum of one minute. The minute will allow oil todrain back into the crankcase.


1. Open the engine enclosure. The oil level dipstickis located on the front of the engine.

2. Maintain the oil level between the “ADD” mark andthe “FULL” mark on the dipstick.

Note: When you operate the machine on severeslopes, the oil level in the engine crankcase must beat the “FULL” mark on the dipstick.


3. Clean the oil fi ller cap. Remove the oil fi ller cap. If necessary, add oil.

4. Install the oil fi ller cap.



37/68


Engine Oil Sample - Obtain

i01950580


SMCS Code: 1000-008; 7542-008

S/N: SLD1-531

S/N: SLE1-1250

S/N: SLF1-791


Park the machine on level ground. Fully retractthe boom and fully lower the boom. Move thetransmission control to the NEUTRAL position andengage the parking brake.

Obtain an engine oil sample while the engine isrunning. Remove the dipstick. Use a sampling gunin the tube for the dipstick in order to obtain an oilsample from the engine.

Use S·O·S Oil Analysis in order to monitor thecondition of your engine.

For additional information, refer to SpecialPublication, SEBU6250, “Caterpillar Machine FluidsRecommendations”, “S·O·S Oil Analysis”.

i02063237


SMCS Code: 1000-008; 7542-008

S/N: SLD600-Up

S/N: SLE1350-Up

S/N: SLF900-Up

S/N: JRK1-Up

Park the machine on level ground. Fully retract andfully lower the boom. Move the transmission controlto the NEUTRAL position and ensure that the parkingbrake is engaged.


The oil sampling valve for the engine oil is located onthe engine oil filter base.

Refer to Special Publication, SEBU6250, “S·O·S Oil Analysis” for information that pertains to obtaining asample of the engine oil. Refer to Special Publication,PEHP6001, “How To Take A Good Oil Sample” for more information about obtaining a sample of theengine oil.

Use S·O·S Oil Analysis in order to monitor thecondition of your engine.


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160 SEBU7600-12Maintenance SectionEngine Oil and Filter - Change

i02429549

Engine Oil and Filter - Change

SMCS Code: 1318-510

S/N: SLD1-531

S/N: SLE1-1250

S/N: SLF1-791

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact skin.

NOTICECare must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.



Note: Change the engine oil and the fi lter after every500 hours. This is the normal interval provided thatthe following conditions are met:

• Only genuine Caterpillar fi lters must be used.

• Only Caterpillar Multigrade Diesel Engine Oil(DEO) to specification CG-4 or an equivalent mustbe used. Refer to Operation and MaintenanceManual, “Lubricant Viscosities” and SpecialPublication, SEBU6250, “Caterpillar MachineFluids Recommendations” for more detailedlubricant information.

• Working conditions must be clean and applicationsmust be light. Obtain an S·O·S oil sample at thefirst 250 hours in order to determine if the oilchange interval can be decreased.

• The sulfur content of the fuel must be between0.05% to 0.5%. If a higher percentage of sulfur ispresent in the fuel, the engine oil and the fi lter willneed to be changed more often. 0.5% to 1.0% of sulfur content will require the engine oil and thefilter to be changed after every 250 hours. 1.0% to1.5% of sulfur content will require the engine oiland the fi lter to be changed after every 125 hours.

1. Before you drain the engine oil, park the machineon a level surface and engage the parking brake.The engine oil should be warm before you drainthe oil. Stop the engine.



3. Pull the open end of hose (1) from the rear, rightside of the subframe and position the end of thehose into a suitable container. Turn shutoff valve(2) counterclockwise in order to drain the engine

oil from the crankcase. Turn the shutoff valveclockwise in order to close the shutoff valve. Allowthe oil to drain from the hose. Then, store the openend of the hose on the subframe.

4. Remove old engine oil filter (3) with a filter wrench.

Note: The filter will contain oil.

5. Clean the filter housing base. Ensure that all of the old gasket is removed.

6. Apply a thin fi lm of clean engine oil to the seal of the new engine oil filter.

7. Install new engine oil filter (3) hand tight until theseal of engine oil filter (3) contacts the base. Notethe position of the index marks on the filter inrelation to a fixed point on the fi lter base.

Note: There are rotation index marks on engine oilfilter (3) that are spaced 90 degrees or 1/4 of a turnaway from each other. When you tighten engine oilfilter (3), use the rotation index marks as a guide.


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8. Tighten the filter according to the instructions thatare printed on the fi lter. Use the index marks asa guide. For non-Caterpillar filters, refer to theinstallation instructions that are provided by thesupplier of the fi lter.

Note: You may need to use a Caterpillar strapwrench, or another suitable tool, in order to turnthe filter to the amount that is required for finalinstallation. Make sure that the installation tool doesnot damage the filter.

9. Remove filler cap (4) and fill the crankcase withnew oil.

Refer to Operation and Maintenance Manual,“Lubricant Viscosities” for more information on thetype of oil that is required. Refer to Operation andMaintenance Manual, “Capacities (Refill)” for moreinformation on the quantity of oil that is required.

10. Check that the parking brake is engaged and thatthe transmission is in NEUTRAL and then startthe engine. Operate the engine for five minutes atlow idle. Inspect the engine for leaks and makeany repairs that are necessary.

11. Stop the engine. Wait for two minutes after youstop the engine. Stopping the engine allows oilto drain back to the crankcase. Check the oillevel. If necessary, add oil. Maintain the oil levelbetween the “ADD” mark and the “FULL” mark onthe dipstick. Install the filler cap.


i02429550


SMCS Code: 1318-510

S/N: SLD600-Up

S/N: SLE1350-Up

S/N: SLF900-Up

S/N: JRK1-Up

Hot oil and hot components can cause personalin jury. Do not allow hot oil or hot components tocontact skin.





Note: Change the engine oil and the fi lter after every500 hours. This is the normal interval provided that

the following conditions are met:

• Only genuine Caterpillar fi lters must be used.

• Only Caterpillar Multigrade Diesel Engine Oil(DEO) to specification CG-4 or an equivalent mustbe used. Refer to Operation and MaintenanceManual, “Lubricant Viscosities” and SpecialPublication, SEBU6250, “Caterpillar MachineFluids Recommendations” for more detailedlubricant information.

• Working conditions must be clean and applicationsmust be light. Obtain an S·O·S oil sample at the

first 250 hours in order to determine if the oilchange interval can be decreased.

• The sulfur content of the fuel must be between0.05% to 0.5%. If a higher percentage of sulfur ispresent in the fuel, the engine oil and the filter willneed to be changed more often. 0.5% to 1.0% of sulfur content will require the engine oil and thefilter to be changed after every 250 hours. 1.0% to1.5% of sulfur content will require the engine oiland the fi lter to be changed after every 125 hours.

1. Before you drain the engine oil, park the machineon a level surface and engage the parking brake.

The engine oil should be warm before you drainthe oil. Stop the engine.

2. Open the engine access door.


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162 SEBU7600-12Maintenance SectionEngine Valve Lash - Check


3. Position the end of hose (3) into a suitablecontainer. Turn shutoff valve (2) counterclockwisein order to drain the engine oil from the crankcase.Turn the shutoff valve clockwise in order to closethe shutoff valve. Allow the oil to drain from thehose.

4. Remove old engine oil filter (1) with a filter wrench.

5. Clean the filter housing base. Ensure that all of the old seal is removed.

6. Apply a thin film of clean engine oil to the seal of the new engine oil filter.

7. Install new engine oil fi lter (1) hand tight until theseal of engine oil fi lter (1) contacts the base. Notethe position of the index marks on the filter inrelation to a fixed point on the fi lter base.

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

8. Tighten the filter according to the instructions thatare printed on the fi lter. Use the index marks asa guide. For non-Caterpillar filters, refer to theinstallation instructions that are provided by thesupplier of the fi lter.

Note: You may need to use a Caterpillar strapwrench, or another suitable tool, in order to turnthe filter to the amount that is required for finalinstallation. Make sure that the installation tool doesnot damage the filter.


9. Remove filler cap (4) and fill the crankcase withnew oil.

Refer to Operation and Maintenance Manual,“Lubricant Viscosities” for more information on thetype of oil that

Documents

SEBU7600-12 M Telehandler