Check Engine Oil Level

WARNING

Hot Surface

Hot components can cause serious personal injury.

1. Turn off the machine and allow the components to cool down before starting maintenance work.

2. Use Personal Protective Equipment (PPE).

3. Be careful when draining hot fluids.

4. Do not handle flammable fluids near hot surfaces, sparks, or open flames.

WARNING

Burning Hazard

High oil temperature can cause serious personal injury.

1. Shut off the engine.

2. Use working gloves, face shield, and cover your arms with long sleeves.

Precondition

• The diesel engine is turned off.

1. •
   1.
   Check that the oil level is between the upper and lower mark on the dipstick (B).

   

2. •
   2.
   Top up the oil through the filler cap (A), if necessary.

   NOTE

   Only use engine oil that the engine manufacturer approves for engine and type of operation.

Replace Oil Filter

1. •
   1.
   Replace engine oil filter (A).

   See Reference Documentation
   Diesel engine instruction manual

Replace Fuel Filter

NOTE

The filter cannot be cleaned and must be replaced.

1. •
   1.
   Loosen the fuel filter (A) using a suitable tool and remove the filter.
2. •
   2.
   Collect any residual fuel.

   

3. •
   3.
   Clean the filter holder sealing surface.
4. •
   4.
   Oil the rubber seal of the new fuel filter (A) sparingly.
5. •
   5.
   Screw in the filter by hand until the gasket is home.

   

6. •
   6.
   Tighten the filter an extra half turn.

   

7. •
   7.
   Check that the fuel filter (A) does not leak.

Draining Condensate from Fuel Tank

1. •
   1.
   Drain the condensate via the drainage panel. The drainage panel is on the left-hand side of the machine between the wheels.
2. •
   2.
   Use the jack to tilt the machine so that the tank drains completely.
3. •
   3.
   Tighten the plug so the diesel fuel cannot leak out.

Fill Fuel Manually

WARNING

Flammable and Toxic Liquid

Fuel is toxic and can cause injury. Fuel is flammable and causes burns, serious personal injury, or death.

1. Shut off the engine.

2. Use personal protective gear.

3. Do not handle flammable fluids near hot surfaces, sparks, or flames.

4. Clean up fuel spills.

NOTICE

Damage to Diesel Engine or Particle Filter

The use of fuel of a lower quality other than recommended by the diesel engine manufacturer, damages the diesel engine and particle filter.

1. Always use the recommended fuel.

Avoid filling fuel if there is a risk of contamination, for example, in windy or wet weather, or when there is dust in the air.

Precondition

• The diesel engine is turned off.

• The tank and tank cover are clean.

1. •
   1.
   Remove the filler cap (A).
2. •
   2.
   Fill with fuel.

   Diesel Tank Volume
   67 L (18 gal)

Check Diesel Engine Components

1. •
   1.
   Check for signs of leakage on the hydraulic pumps (C).
2. •
   2.
   Check that the diesel engine oil level is between the two marks on the dipstick (E).
3. •
   3.
   Check the diesel engine (D) for leaks.
4. •
   4.
   Check for wear and tension on the belts (B).
5. •
   5.
   Check connections and couplings on the intake manifold on the air filters (A).

Check Diesel Engine

1. •
   1.
   Check the pump attachment on the hydraulic pumps (B).
2. •
   2.
   Check for cracks and wear on the rubber coupling between diesel engine (A) and hydraulic pumps (B).
3. •
   3.
   Check the mountings on the diesel engine (A). 8 bolts M10, 8 bolts M12.

Replace Engine Oil

1. •
   1.
   Replace the engine oil and drain plug on the left-hand side of the engine (A).

Check Valve Clearance

1. •
   1.
   Check the valve clearance.

Belts

Alternator Belt and Compressor Belt

A	Compressor Belt
B	Alternator Belt

The alternator belt and compressor belt are changed when required or in accordance with the maintenance schedule.

Checking Belt Tension with Tension Gauge

1. •
   1.
   Press down the arm (A) in the gauge.
2. •
   2.
   Place the guide (C) on the belt (B) between the two belt pulleys, making sure that the stop is lateral.
3. •
   3.
   Press the button (D) at right angles to the belt (B) so that the spring can be felt or heard to release.
4. •
   4.
   Lift the gauge carefully without changing the position of arm (A).
5. •
   5.
   Read off the value at the intersection (arrow) of the scale (E) and the arm (A).
6. •
   6.
   Readjust the tension if necessary.

Check Belt

1. •
   1.
   Check the tension on the compressor belt (A).
2. •
   2.
   Check the tension on the alternator belt (B).

Replace Compressor Belt

1. •
   1.
   Loosen the screws (A) that secure the compressor.
2. •
   2.
   Loosen the adjust screw (B) until the belts can be removed.
3. •
   3.
   Remove the belts by threading them through the gap.

   NOTE

   Change both belts at the same time.

4. •
   4.
   Adjust the belt tension with the adjustment screw (B).

   NOTE

   Check the belt tension using a tension gauge. Belt tension must be 1921 N at a downward curvature of 7.19 mm (0.283 in) .

5. •
   5.
   Tighten the screws (A) 20 Nm (14.75 lb ft).

Alternator Belt Change

The alternator belt must not, as a rule, need changing. See instructions for the diesel engine and CAT instructions Online.

Air System

• The air filters consist of a filter housing (F) with the following:

  • Cover (A)

  • Clamps (B)

  • Main cartridge (D)

  • Safety cartridge (E)

  • Evacuation valve (C)

• Air filtration is done in two stages. The first stage comprises a cyclone and the second stage a normal filter.

• Both filtration stages take place in the filter housing.

• The filter performance improves right up until it becomes clogged.

• There is an indicator that is on the filter housing to advise when the filter cartridge is clogged.

• The indicator is connected to the display in the cab.

• A warning symbol comes on in the status bar at the bottom of the display if a filter is starting to clog.

It is important to keep the air filter and air cleaner in good condition so that the exhaust gases are as clean as possible. Repeated disassembling and assembly can damage the gasket between the insert and the filter housing. Smoke and poor engine performance can be an indication of clogged filters.

Air Filter Indicator Function

To ensure filter clogging is detected, the function of the air filter indicator must be checked regularly. This is done by gradually covering the air intake with a piece of wood or similar. The sensor (A) should then send a signal and the warning symbol or the warning light should come on. If a warning is not indicated, start by checking the cable connections. If there are no problems with the connections, then the sensor is faulty and must be replaced. The sensor is not included in the filter housing, but is ordered separately.

Check Air Filter Indicator Lamp Function

NOTE

Check that no dirt or other particles enter the filter housing.

1. •
   1.
   Remove the air intake cover on the filter housing.
2. •
   2.
   Allow the engine to idle.
3. •
   3.
   Use a piece of board or similar to cover part of the air intake.
4. •
   4.
   Check that the alarm indicator lamp is turned on.

   Step result

   The alarm indicator lamp is turned on.

   NOTE

   If an alarm indicator lamp is not turned on, check cable connections. If there are no problems with the connections, then the alarm indicator lamp (A) is faulty and must be replaced.

5. •
   5.
   Stop the engine and reset the alarm indicator lamp (A) by pressing the button on the indicator lamp.
6. •
   6.
   Install the air intake cover.

Replace Air Filter Cartridge

NOTE

Do not clean the filter cartridge.

1. •
   1.
   Remove the clamps (A).
2. •
   2.
   Remove the cover (B).
3. •
   3.
   Remove the filter cartridge (C).
4. •
   4.
   Clean inside the filter housing and lid.
5. •
   5.
   Check the evacuation valve (D).
6. •
   6.
   Install a new filter cartridge (C).
7. •
   7.
   Install the cover (B) and attach the clamps (A).

Replace Air Filter Safety Cartridge

1. •
   1.
   Remove the clamps (A).
2. •
   2.
   Remove the cover (B).
3. •
   3.
   Remove main filter.
4. •
   4.
   Clean the filter housing.
5. •
   5.
   Pull out the safety cartridge (C).
6. •
   6.
   Cover the air outlet with adhesive tape.
7. •
   7.
   Clean inside the filter housing and the lid.
8. •
   8.
   Install the new safety cartridge (C).
9. •
   9.
   Install the cover (B) and attach the clamps (A).

Check Air Filter

1. •
   1.
   Inspect the air filters (A).