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R1700 SERIES II
LOAD HAUL DUMP
Maintenance Intervals
Excerpted from Operation & Maintenance Manual ((SEBU7320-02)
© 2007 Caterpillar
All Rights Reserved
®
100
Maintenance Section
Maintenance Intervals
Maintenance Intervals
Service When Required
Fuses and Circuit Breakers - Replace/reset ......... 101
Fuel System - Service when loss of power ............ 133
Windshield Wipers and Washer - Replace
blades/fill reservoirs ................................................ 103
Electronic Control Module (ECM) - Investigate
engine derate/shutdown ........................................ 104
Filter Inspection - Inspect used filter for debris ...... 105
Towing Brake Release System - Reset striker ...... 105
Every 10 Service Hours or Daily
Walk-Around Inspection - Inspect machine .......... 106
Engine Crankcase Oil - Check oil level .................. 108
Transmission System Oil - Check oil level ............. 109
Hydraulic Tank Oil - Check oil level ....................... 109
Cooling System - Check coolant level ................... 110
Engine Air Intake System - Service filters .............. 111
Fuel Tank - Drain the water and sediment ............. 115
Seat Belt - Inspect ................................................ 115
Brakes - Test ......................................................... 116
Indicators and Gauges - Test ............................... 121
Backup Alarm - Test ............................................. 121
Fan and Alternator Belts - Inspect/adjust ............. 122
Bucket Pivot Pins - Lubricate ............................... 123
Bucket Tilt Linkage Bearings - Lubricate .............. 123
Bucket Tilt Cylinder and Tilt Lever
Bearings - Lubricate .............................................. 124
Lift Arm and Cylinder Linkage
Bearings - Lubricate .............................................. 125
Frame Pivot Bearings - Lubricate ......................... 125
Steering Cylinder Bearings - Lubricate ................. 126
Rear Axle Trunnion Bearings - Lubricate .............. 126
Centralized Lubrication System - Lubricate
fittings .................................................................... 127
Automatic Lubrication System - Check ................ 128
Scrubber Water Tank - Check water level ............. 128
Fire Extinguisher System - Check ........................ 129
Every 50 Hour Service Hours or Weekly*
Cab Air System - Clean filters ............................... 130
Tires - Check inflation pressure .............................. 131
Fuel System - Drain water separator ..................... 131
Every 250 Service Hours or Monthly*
Engine Valve Lash/Unit Injector Preload Adjust on new or reconditioned engines, then at
normal interval thereafter ........................................ 158
Engine Oil and Filter - Change .............................. 132
Fuel System - Service filters .................................. 133
Cooling System (Conventional Coolant/Antifreeze) Check coolant/add coolant additive. This
maintenance procedure is for machines using
conventional coolant/antifreeze only ....................... 136
Differentials and Final Drives - Check oil level ...... 137
Batteries - Check .................................................. 138
Low Transmission Oil Pressure Automatic Brake
Application (ABA) System - Test operation ........... 140
Cylinder Head Ground Stud - Check ................... 141
Fan Bearing (R1700-127 to 195) - Lubricate ........ 141
Drive Shaft Universal Joints, Splines and
Bearings - Lubricate .............................................. 142
Escape Door Pivot Pins - Lubricate/check ........... 143
Air Conditioner - Test operation/adjust belt ........... 143
Towing Brake Release System - Lubricate striker
shaft ....................................................................... 145
Fire Extinguisher System - Check ........................ 145
Every 500 Service Hours or 3 Months*
Transmission Oil Filter - Change ........................... 146
Hydraulic Oil System - Change filters .................... 147
Brake Charge Pump Filter - Change .................... 148
Engine Crankcase Breather - Clean ..................... 148
Fuel Tank Cap and Fill Screen - Clean ................. 149
Fire Extinguisher System - Check ........................ 150
Every 1000 Service Hours or 6 Months*
Transmission Oil - Change .................................... 151
Differentials and Final Drives - Change oil ............ 153
Brake Accumulators - Check pressures ............... 154
Ride Control Accumulator - Check pressure ........ 156
FOPS - Inspect ...................................................... 156
Fire Extinguisher System - Check ........................ 157
Every 2000 Service Hours or 1 Year*
Engine Valve Lash/Unit Injector
Preload - Check/adjust .......................................... 158
Engine Valve Rotators - Check ............................. 158
Engine Mounts and Crankshaft Vibration
Damper - Check/inspect ....................................... 159
Hydraulic Tank Oil - Change oil ............................ 160
Hydraulic Tank Vacuum Breaker - Clean ............. 161
Wheel Brakes - Check wear .................................. 162
Towing Brake Release System - Check operation ... 162
Fire Extinguisher System - Check ........................ 164
Every 3000 Service Hours or 2 Years*
Cooling System (Conventional Coolant/Antifreeze) Clean/flush/change coolant on machines using
conventional coolant/antifreeze .............................. 165
Cooling System (Extended Life Coolant/Antifreeze) Add "Extender". This maintenance procedure is for
machines using Extended Life Coolant/
Antifreeze only ......................................................... 166
Every 6000 Service Hours or 4 Years*
Cooling System (Extended Life Coolant/Antifreeze) Clean/flush/change coolant on machines using
Extended Life Coolant/Antifreeze only .................... 167
* First Perform Previous Service Hours Items.
101
Maintenance Section
When Required
Service When Required
You must read and understand the warnings and
instructions contained in the Safety Section of this
manual before performing any operation or
maintenance procedures.
Fuses and Circuit Breakers
Replace Fuses
Fuses - They protect the electrical system
from damage caused by overloaded circuits.
Change a fuse if the element separates. If the
element of a new fuse separates, have the circuit
checked and repaired.
NOTICE
Reset Circuit Breakers (R1700-127 to 148)
Circuit Breakers - They protect the electrical
system from damage caused by overloaded
circuits. Push the button in to reset the circuit
breaker. If working properly, the button will remain
depressed. If the button does not stay in or comes out
shortly after being reset, have the appropriate electrical
circuit checked.
NOTICE
Replace circuit breakers with the same type and size only.
Otherwise, electrical damage can result.
If it is necessary to reset circuit breakers frequently, an
electrical problem may exist. Contact your Elphinstone
dealer.
Replace fuses with the same type and size only. Otherwise,
electrical damage can result.
If it is necessary to replace fuses frequently, an electrical
problem may exist. Contact your Elphinstone dealer.
1
2
3
4
5
6
7
8
1
The above illustration details circuit breaker layout.
Located in battery compartment.
(1) 675 AMP Fuse - Fusible link.
(1) 30 AMP C.B. - Air conditioning (if equipped).
(2) 15 AMP C.B. - Rear lights, bucket positioner.
(3) 15 AMP C.B. - Interior light (if equipped), washers/
wipers (if equipped), 24/12 V converter (if equipped),
(4) 15 AMP C.B. - Ride control (if equipped), reverse
alarm, hydraulic pilot valve detents.
(5) 15 AMP C.B. - Transmission control, park brake
control.
(6) 15 AMP C.B. - Remote control (if equipped).
(7) 15 AMP C.B. - ECM & CMS
(8) 30 AMP (Automatic) - Front lights, panel lights.
102
Maintenance Section
When Required
Reset Circuit Breakers (R1700-149 & Up)
10
9
Circuit Breakers - They protect the electrical
system from damage caused by overloaded
circuits. Push the button in to reset the circuit
breaker. If working properly, the button will remain
depressed. If the button does not stay in or comes out
shortly after being reset, have the appropriate electrical
circuit checked.
NOTICE
Replace circuit breakers with the same type and size only.
Otherwise, electrical damage can result.
Located in right hand side of the engine bay.
(9) 15 AMP C.B. - ECM/CMS event recorder.
(10) 80 AMP C.B. - Main.
If it is necessary to reset circuit breakers frequently, an
electrical problem may exist. Contact your Elphinstone
dealer.
1
2
3
4
5
6
7
8
The above illustration details circuit breaker layout.
(1) 15 AMP C.B. - Remote control (if equipped).
(2) 15 AMP C.B. - Remote control switch (if equipped),
CMS, fire system control (if equipped).
(3) 15 AMP C.B. - Residual brake pressure/stop light (if
equipped), loadrite (if equipped), cassette player (if
equipped), washers/wipers (if equipped), interior light
(if equipped).
(4) 15 AMP C.B. - Bucket positioner, auto lube system,
horn, hydraulic pilot valve detents, ride control (if
equipped), electronic transmission controller, backup
alarm.
(5) 15 AMP C.B. - Brake control, exhaust back
pressure control (if equipped).
(6) 15 AMP C.B. - ECM/CMS event recorder.
(7) 30 AMP (Automatic) - Rear lights.
(8) 30 AMP (Automatic) - Front lights, panel lights.
103
Maintenance Section
When Required
Windshield Wipers and
Washer (If Equipped)
Replace Blades
9
Located behind lower dash panel.
(9) 30 AMP (Automatic) - Air conditioning (if equipped).
10
Inspect the front, rear and side windshield wiper
blades. Replace any blades that are worn or damaged,
or if streaking occurs.
Fill Washer Reservoir
NOTICE
Located above torque converter in the engine bay.
When operating in freezing conditions, use Caterpillar nonfreezing window washer solvent or equivalent. System
damage can result from freezing.
(10) 80 AMP C.B. - Main.
Check the level of the windshield washer fluid reservoir
and fill if necessary.
104
Maintenance Section
When Required
Electronic Control Module (ECM)
If the machine will not restart, or if the condition persists,
have the machine inspected and the fault corrected.
Investigate Engine Derate/Shutdown
NOTE: For a detailed description of the ECM refer to
3176B Engine Electronic Troubleshooting, Form No.
SENR6497.
1
2
Electronic Control Module (ECM) - The ECM provides
electronic control of the 3176B engine fuel injection
system. It includes warning, derate, emergency
shutdown and diagnostic facilities.
Warning
Engine diagnostics warning light (1) will come on if the
ECM detects a malfunction in the system.
Derate
Under certain critical conditions the ECM will reduce
available engine power (derate) to conserve the engine.
The engine diagnostic warning light (1) will flash
whenever the engine is derated.
Shutdown
Under emergency conditions the ECM will shutdown
the engine. The engine diagnostic warning light (1) will
come on when the engine is shutdown. Depending on
the condition which caused the engine to shutdown,
the engine may be able to be restarted after a period of
up to 80 seconds.
Diagnostics
The conditions causing warning, derate and emergency
shutdown may be diagnosed by the operator. Hold
diagnostic test switch (2) ON until engine diagnostic
light (1) starts flashing. The light will flash a diagnostic
code. The code may be interpreted by referring to the
Engine Diagnostic Codes decal located in the
operators compartment.
Located in the operators compartment.
105
Maintenance Section
When Required
Filter Inspection
Towing Brake Release System
(If Equipped)
Inspect Used Filter for Debris
Reset Striker
Reset the towing brake release system striker before
working on or operating the machine. Failure to do
so may result in the machine moving unexpectedly,
causing serious personal injury or death.
Ensure the machine is parked on a level surface and
the wheels blocked securely prior to resetting the
striker.
Use a 4C5084 Filter Cutter to cut the filter element
open. Spread pleats apart and inspect the element for
metal and other debris. An excessive amount of debris
in the filter element can indicate a possible failure.
If the towing brake release system has been activated,
the striker will need to be reset. Reset the striker and
repair any machine faults before returning the machine
to operation.
Use a magnet to differentiate between ferrous and
nonferrous metals found in the filter element.
Ferrous metals can indicate wear on the steel and cast
iron parts.
3
2
1
Nonferrous metals can indicate wear on the aluminium
parts of the engine, such as main, rod and/or
turbocharger bearings.
Due to normal wear and friction, it is not uncommon to
find small amounts of debris in the filter element.
Consult your Elphinstone dealer to arrange for further
analysis if an excessive amount of debris is found.
Use of an oil filter element not recommended by
Elphinstone can result in severe engine damage to
engine bearings, crankshaft and other parts. This can
result in larger particles in unfiltered oil entering the
lubricating system and causing damage.
When striker knob (1) is struck, the knob pushes the
shaft in to activate striker valve (3). When the shaft
moves in, cotter pin (2) will shear allowing the shaft to
move in fully to activate the striker valve. The shaft is
held in the activated position by spring force.
Prior to returning the machine to operation, move the
shaft out to the released position, remove the sheared
cotter pin and fit a new cotter pin to the striker shaft.
NOTICE
Always fit the correct part number cotter pin in the striker
shaft. Failure to do so may prevent the towing brake
release system from functioning correctly.
106
Maintenance Section
Every 10 Service Hours or Daily
Every 10 Service Hours or Daily
You must read and understand the warnings and
instructions contained in the Safety Section of this
manual before performing any operation or
maintenance procedures.
Walk-Around Inspection
Inspect Machine
NOTICE
Accumulated grease and oil on a machine is a fire hazard.
Remove this debris with steam cleaning or high pressure
water, at least every 1000 hours or each time any significant
quantity of oil is spilled on a machine.
NOTE: Keep a close watch for leaks. If leaking is
observed, find the source and correct the leak. Check
the fluids level more frequently than the recommended
periods if leaking is suspected or observed.
Inspect the bucket and linkage for damage or
excessive wear. Repair if damaged.
Inspect the lights for broken bulbs and lenses. Replace
if broken.
Inspect and remove any trash build-up in the engine
compartment.
Inspect the cooling system for leaks, faulty hoses and
trash build-up. Correct any leaks and remove any
trash from the radiator.
Inspect all engine attachment belts for worn, cracked
or frayed edges. Replace if worn, cracked, frayed or
broken.
Inspect the hydraulic system for leaks. Inspect the
tank, cylinder rod seals, hoses, tubes, plugs, joints and
fittings. Correct any leaks.
Inspect the air intake precleaner for damage and rotor
operation. Check the air restriction indicator.
107
Maintenance Section
Every 10 Service Hours or Daily
Window Cleaning
Inspect the differentials and final drives (front and rear)
under the machine for leaks.
Inspect tires (front and rear) for damage and proper
inflation. Replace any missing valve caps.
Inspect transmission and torque converter updrive for
leaks.
Inspect the wheel brakes for leaks.
Be sure the covers and guards are firmly in place.
Inspect for damage.
Inspect the steps, walkways and handholds for their
condition and cleanliness. Inspect the Falling Objects
Protective Structure (FOPS) for damage. If repair is
necessary, contact your Elphinstone dealer. Tighten
any loose FOPS bolts.
Inspect the operator's compartment for cleanliness.
Keep it clean.
Use commercially available window cleaning solutions
to clean the windows. Clean the outside windows from
the ground, unless handholds are available.
108
Maintenance Section
Every 10 Service Hours or Daily
Engine Crankcase Oil
Check the Oil Level
2
NOTICE
Do not overfill the crankcase. Engine damage can result.
The dipstick is located in the right hand side of the
engine compartment.
1. The machine must be level with the parking
engaged and the engine stopped.
1
2. Maintain the oil level between the ADD and FULL
marks on dipstick (1) with the engine stopped.
3.
Remove oil filler cap (2) and add oil if necessary.
4.
Clean and install the filler cap.
109
Maintenance Section
Every 10 Service Hours or Daily
Transmission System Oil
Hydraulic Tank Oil
Check the Oil Level
Check the Oil Level
Check the transmission oil level with the machine level,
the engine running at low idle and the oil at normal
operating temperature.
3
1. Open the access cover located on the platform
near the operator's station.
1
1
2
The hydraulic oil tank is located on the right hand side
of the machine.
1. Maintain the oil level above the ADD COLD mark
on sight gauge (1) with the engine stopped and the
bucket level on the ground.
2. Maintain the oil between the LOW and FULL marks
on dipstick (1) at LOW IDLE.
3.
Remove oil filler cap (2) and add oil if necessary.
4.
Clean and install the filler cap.
5.
Close the access cover.
2
2. Open the hydraulic tank access cover located on
the upper right hand side of the machine.
3. Relieve the hydraulic tank pressure by pushing on
top of relief valve (2) before removing the oil filler cap.
4. Remove oil filler cap (3) slowly to relieve any
remaining pressure. Add oil, if necessary, through the
fill tube.
5.
Clean and install the filler cap.
110
Maintenance Section
Every 10 Service Hours or Daily
Cooling System
Check the Coolant Level
5. Inspect the radiator core for debris and clean if
necessary.
1. Maintain the coolant level in the sight gauge
located on the right hand side of the machine. If it is
necessary to add coolant daily, check for leaks.
2. If coolant level is low, remove the radiator cap
slowly to relieve pressure. Add coolant as required to
within 13 mm (1/2 in.) of the bottom of the fill pipe or to
the proper level on the sight gauge.
3. Inspect the cap and cap seal for damage, deposits
or foreign material. Clean the cap with a clean cloth or
replace the cap if it is damaged.
4.
Install the cap.
Compressed air is preferred, but high pressure water
or steam can be used to remove dust, leaves and
general debris from the radiator. Clean as required by
condition of radiator.
111
Maintenance Section
Every 10 Service Hours or Daily
Engine Air Intake System
Check the Air Intake Precleaner
Service the Filter Elements
NOTICE
To prevent engine damage, service the air cleaner only with
the engine stopped.
NOTICE
Some machines use radial seal type air cleaners. To avoid
engine damage, use only radial seal replacement filters.
Others will not seal.
Radial seal filter gasket design and location are critical to
proper air cleaner operation. Use only Caterpillar
replacements.
1. Inspect the air intake precleaner visually for
damage.
2.
Check the air intake precleaner rotor operation.
3. Periodically check the rotor bearing and replace if
necessary.
Service the air cleaner daily or if the yellow piston in the
filter element indicator moves into the red zone with the
engine running at high idle. Stop the engine.
112
Maintenance Section
Every 10 Service Hours or Daily
Service the Primary Element
1
3.
1.
Remove air cleaner cover (1).
2
Clean the inside of the air cleaner housing.
4. Clean and inspect the primary element. See
Cleaning Primary Elements.
5.
Install a clean primary element.
6.
Clean and install the cover.
If the yellow piston in the filter element indicator moves
into the red zone after starting the engine, or the
exhaust smoke is still black after installation of a clean
primary element, install a new primary filter element.
The primary filter element should be replaced after
being cleaned a maximum of six times. Replace the
element once a year even though it has not been
cleaned six times.
2. Remove primary filter element (2) from the air
cleaner housing.
113
Maintenance Section
Every 10 Service Hours or Daily
Change the Secondary Element
Cleaning Primary Elements
NOTICE
NOTICE
Always replace the secondary filter element. Never attempt
to reuse it by cleaning.
Do not clean the filter elements by bumping or tapping
them. Do not use filter elements with damaged pleats,
gaskets or seals. Engine damage could result.
The secondary filter element should be replaced at the time
the primary element is serviced for the third time.
The secondary filter element should also be replaced if the
yellow piston in the filter element indicator enters the red
zone after the installation of a clean primary element, or if
the exhaust smoke is still black.
1. Remove the housing cover and the primary
element.
Make sure the cleaned filter elements are completely dry
before installing into the filter housing. Water remaining in
the elements can cause false indications of contamination
in Scheduled Oil Sampling test results.
Filter elements can be cleaned with pressure air,
pressure water, or detergent washing.
Pressure Air - 205 kPa (30 psi) Maximum
1
2. Remove bolts (1) that hold the secondary filter
element to the housing. Remove the secondary filter
element.
3. Cover the air inlet opening. Clean the inside of the
air cleaner housing.
4. Inspect the gasket between the air inlet pipe and
the housing. Replace it if it is damaged.
5. Uncover the air inlet opening. Install a new
secondary element.
6. Install bolts (1) that hold the secondary filter
element to the housing. Torque the bolts to 27 ± 7
N•m (20 ± 5 lb.ft.).
7.
Install the primary element and cover.
1. Direct air along pleats inside and outside of filter
element.
2.
Inspect the element.
114
Maintenance Section
Every 10 Service Hours or Daily
Pressure Water - 280 kPa (40 psi) Maximum
Inspecting the Elements
1. Direct water along pleats inside and outside of filter
element.
1. Inspect the filter elements after cleaning. Do not
use a filter element with damaged pleats, gaskets or
seals.
2.
Rinse and air dry thoroughly.
3.
Inspect the element.
Detergent
1. Wash the element in warm water and non-sudsing
household detergent.
2.
Rinse with clean water and dry thoroughly.
3.
Inspect the element.
2. Wrap and store the clean filter elements in a clean,
dry place.
115
Maintenance Section
Every 10 Service Hours or Daily
Fuel Tank
Seat Belt
Drain the Water and Sediment
Inspect for Wear or Damage
The drain valve is located on the right hand side of the
machine under the fuel tank.
Replace the seat belt after three years of usage,
regardless of appearance.
1
2
1. Open (turn counterclockwise) drain valve (1) and
allow the water and sediment to drain out of opening
(2) into a suitable container.
2.
Close drain valve (1).
Seat belt and mounting hardware must be inspected
for wear or damage before operating the machine.
Replace the belt or mounting hardware if worn or
damaged.
116
Maintenance Section
Every 10 Service Hours or Daily
1.
Brakes
Start the engine and raise the bucket slightly.
Test Service Brake Holding Ability
Personal injury can result if the machine moves while
testing.
If the machine begins to move while testing, reduce
the engine speed immediately, apply the parking
brake and lower the bucket to the ground. Repair the
brake immediately.
NOTICE
Perform the following brake tests at the start of each shift
and before entering a ramp.
Be sure the area around the machine is clear of
personnel and obstructions.
Be sure the steering frame lock link is in the stored
position.
Test the brakes on a dry, level surface.
Fasten the seat belt before testing the brakes.
The following tests are to determine if the service brake
is functional. These tests are not intended to measure
maximum brake holding effort. Brake holding effort
required to hold a machine at a specific engine rpm will
vary from machine to machine. This is due to
differences in engine settings, power train efficiency,
etc., as well as differences in brake holding ability.
Engine rpm at beginning of machine movement, with
service brake applied, should be compared against a
prior test. Use the test as an indication of system
deterioration.
To carry out the brake test, first start the engine and let
the brake oil pressure build up to the operating range.
The parking brake will stay applied until operating oil
pressure has been reached and the control button is
moved to the OFF position (brake released). Once
operating oil pressure has been reached a test of the
brake system can be commenced.
2. Depress the service brake pedal to apply the
service brakes. Release the parking brake.
3. Move the transmission control lever to 2nd speed
forward.
4. Gradually increase the engine speed to high idle.
The machine should not move.
5. Reduce the engine speed to low idle, move the
transmission control lever to NEUTRAL. Engage the
parking brake, lower the bucket to the ground and stop
the engine.
NOTICE
If the machine moved while testing the brakes, contact
your Elphinstone dealer. Have the dealer inspect and, if
necessary, repair the service brakes before returning the
machine to operation.
117
Maintenance Section
Every 10 Service Hours or Daily
Test Parking Brake Holding Ability
NOTICE
2
The standard park brake control button is a pull-to apply
type. When the button is pulled OUT, the brakes will be
applied.
1
Certain mining regulations require machines to be equipped
with a push-to-apply park brake control button. When the
button is pushed IN, the brakes are applied.
Before operating the machine, ensure you are familiar with
the operation of the parking brake control button.
Standard Pull-to-Apply Type
Personal injury can result if the machine moves while
testing.
If the machine begins to move, reduce the engine
speed immediately, apply the service brake and lower
the bucket to the ground. Repair the brake
immediately.
Be sure the area around the machine is clear of
personnel and obstructions.
Be sure the steering frame lock link is in the stored
position.
Test the brakes on a dry, level surface.
Fasten the seat belt before testing the brakes.
The following tests are to determine if the parking
brake is functional. These tests are not intended to
measure maximum brake holding effort. Brake holding
effort required to hold a machine at a specific engine
rpm will vary from machine to machine. This is due to
differences in engine settings, power train efficiency,
etc., as well as differences in brake holding ability.
Engine rpm at beginning of machine movement, with
parking brake engaged, should be compared against a
prior test. Use the test as an indication of system
deterioration.
1.
Start the engine and raise the bucket slightly.
2. Engage the parking brake by pulling parking brake
control button (1) OUT to the ON position (brake
applied).
3.
Push the brake test button (2) IN.
4.
Shift the transmission to 2nd speed FORWARD.
NOTE: The parking brake indicator and the fault light
should flash and the action alarm should sound.
5. Gradually increase the engine speed to high idle.
The machine should not move.
6. Reduce the engine speed to low idle, move the
transmission control lever to NEUTRAL. Lower the
bucket to the ground and stop the engine.
NOTICE
If the machine moved while testing the brakes, contact
your Elphinstone dealer. Have the dealer inspect and, if
necessary, repair the parking brake before returning the
machine to operation.
118
Maintenance Section
Every 10 Service Hours or Daily
Optional Push-to-Apply Type
2
Personal injury can result if the machine moves while
testing.
1
If the machine begins to move, reduce the engine
speed immediately, apply the service brake and lower
the bucket to the ground. Repair the brake
immediately.
Be sure the area around the machine is clear of
personnel and obstructions.
Be sure the steering frame lock link is in the stored
position.
2. Engage the parking brake by pushing parking
brake control button (1) IN to the ON position (brake
applied).
Test the brakes on a dry, level surface.
3.
Push the brake test button (2) IN.
Fasten the seat belt before testing the brakes.
4.
Shift the transmission to 2nd speed FORWARD.
The following tests are to determine if the parking
brake is functional. These tests are not intended to
measure maximum brake holding effort. Brake holding
effort required to hold a machine at a specific engine
rpm will vary from machine to machine. This is due to
differences in engine settings, power train efficiency,
etc., as well as differences in brake holding ability.
NOTE: The parking brake indicator and the fault light
should flash and the action alarm should sound.
Engine rpm at beginning of machine movement, with
parking brake engaged, should be compared against a
prior test. Use the test as an indication of system
deterioration.
1.
Start the engine and raise the bucket slightly.
5. Gradually increase the engine speed to high idle.
The machine should not move.
6. Reduce the engine speed to low idle, move the
transmission control lever to NEUTRAL. Lower the
bucket to the ground and stop the engine.
NOTICE
If the machine moved while testing the brakes, contact
your Elphinstone dealer. Have the dealer inspect and, if
necessary, repair the parking brake before returning the
machine to operation.
119
Maintenance Section
Every 10 Service Hours or Daily
Test Driveline Brake Holding Ability
NOTICE
2
The standard park brake control button is a pull-to apply
type. When the button is pulled OUT, the brakes will be
applied.
1
Certain mining regulations require machines to be equipped
with a push-to-apply park brake control button. When the
button is pushed IN, the brakes are applied.
Before operating the machine, ensure you are familiar with
the operation of the parking brake control button.
Standard Pull-to-Apply Type
2. Release the parking brake by pushing parking
brake control button (1) IN to the OFF position (brake
released).
3.
Push the brake test button (2) IN.
Personal injury can result if the machine moves while
testing.
4.
Shift the transmission to 2nd speed FORWARD.
If the machine begins to move, reduce the engine
speed immediately, apply the service brake and lower
the bucket to the ground. Repair the brake
immediately.
NOTE: The parking brake indicator and the fault light
should flash and the action alarm should sound.
Be sure the area around the machine is clear of
personnel and obstructions.
6. Reduce the engine speed to low idle, move the
transmission control lever to NEUTRAL. Lower the
bucket to the ground and stop the engine.
Be sure the steering frame lock link is in the stored
position.
5. Gradually increase the engine speed to 1600 rpm.
The machine should not move.
NOTICE
Test the brakes on a dry, level surface.
Fasten the seat belt before testing the brakes.
The following tests are to determine if the driveline
brake is functional. These tests are not intended to
measure maximum brake holding effort. Brake holding
effort required to hold a machine at a specific engine
rpm will vary from machine to machine. This is due to
differences in engine settings, power train efficiency,
etc., as well as differences in brake holding ability.
Engine rpm at beginning of machine movement, with
parking brake engaged, should be compared against a
prior test. Use the test as an indication of system
deterioration.
1.
Start the engine and raise the bucket slightly.
If the machine moved while testing the brake, contact your
Elphinstone dealer. Have the dealer inspect and, if
necessary, repair the driveline brake before returning the
machine to operation.
120
Maintenance Section
Every 10 Service Hours or Daily
Optional Push-to-Apply Type
2
Personal injury can result if the machine moves while
testing.
1
If the machine begins to move, reduce the engine
speed immediately, apply the service brake and lower
the bucket to the ground. Repair the brake
immediately.
Be sure the area around the machine is clear of
personnel and obstructions.
Be sure the steering frame lock link is in the stored
position.
2. Release the parking brake by pulling parking brake
control button (1) OUT to the OFF position (brake
released).
Test the brakes on a dry, level surface.
3.
Push the brake test button (2) IN.
Fasten the seat belt before testing the brakes.
4.
Shift the transmission to 2nd speed FORWARD.
The following tests are to determine if the driveline
brake is functional. These tests are not intended to
measure maximum brake holding effort. Brake holding
effort required to hold a machine at a specific engine
rpm will vary from machine to machine. This is due to
differences in engine settings, power train efficiency,
etc., as well as differences in brake holding ability.
NOTE: The parking brake indicator and the fault light
should flash and the action alarm should sound.
Engine rpm at beginning of machine movement, with
parking brake engaged, should be compared against a
prior test. Use the test as an indication of system
deterioration.
1.
Start the engine and raise the bucket slightly.
5. Gradually increase the engine speed to 1600 rpm.
The machine should not move.
6. Reduce the engine speed to low idle, move the
transmission control lever to NEUTRAL. Lower the
bucket to the ground and stop the engine.
NOTICE
If the machine moved while testing the brakes, contact
your Elphinstone dealer. Have the dealer inspect and, if
necessary, repair the driveline brake before returning the
machine to operation.
121
Maintenance Section
Every 10 Service Hours or Daily
Indicators and Gauges
Backup Alarm
Test for Proper Function
Test
Look for broken gauge lenses or indicator lights,
switches, etc.
The back-up alarm is located on the rear of the
machine.
Move the engine start switch to the ON position and
check the CMS Functional Test. Refer to the topic
CMS Functional Test in the Monitoring Systems and
Cab Features section of this manual.
Turn the engine start switch ON to perform the test.
Start the engine.
The alarm should start to sound immediately. It will
continue to sound until the transmission control lever is
moved to NEUTRAL or FORWARD.
Look for inoperative gauges.
Apply the service brake. Move the transmission control
lever to REVERSE.
Turn all machine lights on. Check for proper operation.
Sound the horn.
Stop the engine.
Make any needed repairs before operating.
The sound level can be adjusted by moving the
adjustment on the back of the alarm to meet operating
requirements. The alarm is set at the highest sound
level when shipped from the factory. The setting
should remain on high, unless the job site requires a
lower level.
122
Maintenance Section
Every 10 Service Hours or Daily
Fan and Alternator Belts
Inspect/Adjust
Alternator Belt Adjustment
3
4
2
For maximum engine performance and utilisation of
your engine, inspect the belts for wear and cracking.
Check and adjust the belt tension to minimise belt
slippage which will decrease belt life and cause poor
performance of alternator and any driven equipment.
1.
Inspect the condition of the belts.
2.
Inspect the tension of the alternator belt.
1
1. Loosen alternator bolt (1) and bracket bolt (2).
Loosen locknut (3).
2. Turn adjusting nut (4) until the correct belt tension
is reached. Tighten locknut (3) to 105 ± 20 N•m (75 ±
15 lb. ft.).
3. Tighten alternator bolt (1) and bracket bolt (2) to
105 ± 20 N•m (75 ± 15 lb. ft.).
To check the alternator belt tension, apply 110 N (25
lb.) of force midway between the pulleys. Correctly
adjusted belts will deflect 14 to 20 mm (.562 to .812
in.).
If new belt(s) are installed, check belt adjustment again
after 30 minutes of operation. For multiple belt drive
applications, always replace belts in matched sets.
If only one belt of a matched set is replaced, it will
carry more of a load than the belts not replaced since
the older belts are stretched. The additional load on
the new belt could cause it to break.
4. Re-check the belt tension and if necessary retension the belt.
123
Maintenance Section
Every 10 Service Hours or Daily
Bucket Pivot Pins
Bucket Tilt Linkage Bearings
Lubricate Fittings
Lubricate Fittings
Wipe all fittings before lubricating.
Wipe all fittings before lubricating.
Lubricate one fitting on each of the bucket pivot
bearings (2 points).
Lubricate one fitting for each of the bucket tilt linkage
bearings (2 points).
124
Maintenance Section
Every 10 Service Hours or Daily
Bucket Tilt Cylinder and Tilt Lever
Bearings
Lubricate Fittings
Wipe all fittings before lubricating.
Lubricate one fitting for the bearing at the centre pivot
point of the tilt lever.
Lubricate one fitting for the bearing at the head end of
the tilt cylinder.
Lubricate one fitting for the bearing on the rod end of
the tilt cylinder.
125
Maintenance Section
Every 10 Service Hours or Daily
Lift Arm and Cylinder Linkage
Bearings
Frame Pivot Bearings
Lubricate Fittings
Lubricate Fittings
Wipe all fittings before lubricating.
Wipe all fittings before lubricating.
1
2
3
Lubricate one fitting for the upper pivot bearing.
Lubricate one fitting (1) on each side of the machine for
the rear lift arm bearings (2 points).
Lubricate remote mounted fitting (2) on each side of the
machine for the bearing at the rod end of the lift
cylinders (2 points).
Lubricate remote mounted fitting (3) on each side of the
machine for the bearing at the head end of the lift
cylinders (2 points).
Lubricate one fitting for the lower pivot bearing.
126
Maintenance Section
Every 10 Service Hours or Daily
Steering Cylinder Bearings
Rear Axle Trunnion Bearings
Lubricate Fittings
Lubricate Fittings
Wipe all fittings before lubricating.
Wipe all fittings before lubricating.
The fittings are located in the right hand side of the
machine hitch area.
1
2
Lubricate one fitting on each side of the machine for
the bearing at the rod end of the steering cylinders (2
points).
3
1
4
2
Lubricate remote mounted fitting (1) for the bearing at
the head end of the right steering cylinder.
Lubricate rear trunnion bearing (1) through remote
fitting (3).
Lubricate remote mounted fitting (2) for the bearing at
the head end of the left steering cylinder.
Lubricate front trunnion bearing (2) through remote
fitting (4).
127
Maintenance Section
Every 10 Service Hours or Daily
Centralized Lubrication System
(If Equipped)
Lubricate Fittings
9
Wipe all fittings before lubricating.
The fittings are located in the right hand side of the
machine hitch area.
11
13
15
1
3
5
7
2
10
12
14
16
9. Lubricate the right rear lift arm bearing through
remote mounted fitting (9).
4
6
10. Lubricate the bearing at the head end of the right
lift cylinder through remote mounted fitting (10).
8
11. Lubricate the bearing at the rod end of the right lift
cylinder through remote mounted fitting (11).
12. Lubricate the right bucket pivot pin through remote
mounted fitting (12).
1. Lubricate the upper pivot bearing through remote
mounted fitting (1).
13. Lubricate the bearing at the rod end of the tilt
cylinder through remote mounted fitting (13).
2. Lubricate the bearing at the rod end of the left
steering cylinder through remote mounted fitting (2).
14. Lubricate the tilt lever centre pivot bearing through
remote mounted fitting (14).
3. Lubricate the bearing at the rod end of the right
steering cylinder through remote mounted fitting (3).
15. Lubricate the bearing at the bucket end of the tilt
linkage through remote mounted fitting (15).
4. Lubricate the left rear lift arm bearing through
remote mounted fitting (4).
16. Lubricate the bearing at the tilt lever end of the tilt
linkage through remote mounted fitting (16).
5. Lubricate the bearing at the head end of the left lift
cylinder through remote mounted fitting (5).
6. Lubricate the bearing at the rod end of the left lift
cylinder through remote mounted fitting (6).
7. Lubricate the bearing at the head end of the tilt
cylinder through remote mounted fitting (7).
8. Lubricate the left bucket pivot pin through remote
mounted fitting (8).
128
Maintenance Section
Every 10 Service Hours or Daily
Automatic Lubrication System
(If Equipped)
Scrubber Water Tank (If Equipped)
Check Water Level
Check Operation
2
3
1
Typical Example
1. Check the grease level in the reservoir. Use a
manual grease gun or pump to fill the reservoir through
filler fitting (1) in the pump body.
2. Fill the reservoir to the MAXIMUM indicator (2) on
the reservoir.
NOTE: When filling the reservoir, caution should be
used as extreme pressure and overfilling can cause
damage to the reservoir assembly.
3. With the battery disconnect switch and the engine
start switch in the ON position, trigger a lubrication
cycle by pressing switch (3) (obscured) on the side of
the cover assembly.
4. Observe the stirring paddle in the lubricant
reservoir. When the pump is operating, the stirring
paddle should be rotating.
5.
Check all discharge lines for leakage.
6. Check all injectors are operative. Check all
bearings that are lubricated by the automatic
lubrication system for signs of greasing.
7. Inspect the electrical system for worn or frayed
wiring, damaged connectors or a tripped circuit
breaker.
NOTE: For more information on the automatic
lubrication system, refer to Automatic Lubrication
System, Systems Operation, Testing and Adjusting,
Form No. RENR4503 (1DE1818), in the machine
Service Manual.
The water scrubber tank is located on the left hand
side of the rear frame.
1. Stop the engine. Remove the water scrubber tank
filler cap.
2. Inspect the water level in the tank. If necessary, fill
the water tank with clean water.
3. Inspect the water tank filler cap. If necessary,
replace the seal. Install the filler cap.
4. Check the operation of the water bath scrubber
system.
5. Turn the scrubber water valve to the ON position.
The scrubber will fill with water until the water reaches
a level where it will flow through an overflow pipe and
discharge onto the ground. If this does not happen,
check for a blockage between the tank and scrubber or
scrubber outlet.
6. When the water is flowing from the overflow pipe,
the machine can be started. Run the machine up to
operating temperature and check the scrubber water
valve adjustment. This can be checked by observing
the moisture content of the exhaust gases leaving the
scrubber outlet when the engine is at high idle.
129
Maintenance Section
Every 10 Service Hours or Daily
7. If the gases are hot and dry, the water valve should
be turned (opened) further to the ON position.
8. If there is raw water being blown from the exhaust
outlet, the water valve should be turned (closed) further
to the OFF position. A balance between the two
extremes is ideal.
Fire Extinguisher System
(If Equipped)
Check System
NOTICE
NOTE: For more information on the water bath
scrubber system, refer to Emission Control Systems
Maintenance Manual, Form No. RENR4501 (1DE0734),
in the machine Service Manual.
For detailed information on the fire extinguisher system
service procedures, refer to the fire system manufacturer's
service information.
Perform daily fire extinguisher system checks and
service procedures in accordance with the fire system
manufacturer's service information.
130
Maintenance Section
Every 50 Service Hours or Weekly
Every 50 Service Hours or Weekly
You must read and understand the warnings and
instructions contained in the Safety Section of this
manual before performing any operation or
maintenance procedures.
Cab Pressurizer Filter
Cab Air System (If Equipped)
2
1
Clean Filters
Clean the filter elements weekly or when a reduction of
air circulation in the cab is noticed. If working in less
dusty conditions, the service interval for the air
conditioner filters can be extended.
Air Conditioning Recirculation Filter
1.
Slide the seat forward.
3
1. Inspect the air conditioning filter precleaner cup (1)
visually. The cup should be emptied whenever dirt
reaches the indicator mark.
2. Loosen the wing nut on top of the cap and remove
the cap. Remove and empty the cup.
3. Install the cup and cap. Tighten the wing nut
finger tight only. Do not use a tool to tighten the wing
nut.
4. Periodically remove the precleaner cup and cap
and wash them in water.
5. Loosen clamp bolt (2) and remove the air cleaner
assembly end cover (3). Remove the cab air filter
element.
2. Remove the air conditioning recirculation filter from
the air conditioning box in the cab.
6. Clean the filter element with pressure air or wash
the element in warm water and a nonsudsing
household detergent.
3. Clean the filter element with pressure air or wash
the element in warm water and a nonsudsing
household detergent.
7. If washed, rinse the element in clean water and air
dry thoroughly.
4. If washed, rinse the element in clean water and air
dry thoroughly.
8. Refit the element and cover (3). Tighten the cover
clamp bolt (2) finger tight only. Do not use a tool to
tighten the clamp bolt.
5. Install the clean filter element and put the seat
back into position.
131
Maintenance Section
Every 50 Service Hours or
Weekly
Tires
Fuel System
Check the Inflation Pressure
Drain Water Separator
1
2
Measure the tire pressure on each tire. Consult your
Elphinstone dealer for correct load rating and operating
pressures.
Inflate the tires, if necessary. See the Tire Inflation
Information section of this manual.
1. Stop the engine. Clean separator and surrounding
area.
2. Open vent valve (1) located at the top of the water
separator filter.
3. Open drain valve (2) recessed in the bottom of the
canister.
4. Drain the contents into a suitable container until
clean fuel comes out.
5.
Close drain valve (2) to the reservoir.
6.
Close vent valve (1).
7. Refill the water separator by operating the priming
pump. See Priming the Fuel System under Every 250
Service Hours or Monthly.
NOTE: If an excessive amount of water and/or solid
contaminants was drained from the fuel water
separator, drain the fuel tank sediment and clean the
primary fuel filter element.
132
Maintenance Section
Every 250 Service Hours or Monthly
Every 250 Service Hours or Monthly
You must read and understand the warnings and
instructions contained in the Safety Section of this
manual before performing any operation or
maintenance procedures.
5. Install the new filter by hand. When the gasket
contacts the filter base, tighten the filter 3/4 of a turn
more.
Engine Oil and Filter
Change the Oil and Filter
6. Remove the oil filler cap. Fill the crankcase with
new oil. See Lubricant Viscosities and Refill
Capacities. Clean and install the filler cap.
7. Start the engine and allow the oil to warm. Check
for leaks. Stop the engine and check the oil level.
1. Open the crankcase drain valve. Allow the oil to
drain into a suitable container. Close the drain valve.
2. Remove the filter element with a strap-type
wrench. Inspect the used filter element. Refer to Filter
Inspection in the When Required section.
3. Clean the filter housing base. Make sure all of the
old filter gasket is removed.
4. Apply a light coat of clean engine oil to the gasket
of the new filter.
8. Maintain the oil level between the ADD and FULL
marks on the dipstick (engine stopped). Add oil if
necessary.
133
Maintenance Section
Every 250 Service Hours or Monthly
Fuel System
11. Retighten the retaining nut to a torque of 24 ± 4
N•m (18 ± 3 lb ft).
Clean and Change Filters
12. Prime the fuel system. See Prime the Fuel System.
13. Start the engine and check for leaks.
NOTICE
Do not fill fuel filters before installing them. Contaminated
fuel will cause accelerated wear to fuel system components.
Fuel system should be primed prior to starting the engine.
Wash the Primary Filter Element
1
2
1.
Loosen filter case retaining nut (1) (obscured).
2.
Remove case (2) and element from the filter base.
3.
Remove the element from the case.
4. Wash the element and case in clean,
nonflammable solvent.
5. Dry the element using pressure air - 205 kPa (30
psi) maximum.
6.
Inspect the element and replace if damaged.
7.
Clean the filter base.
8.
Inspect the seal. Replace if damaged.
9.
Insert the clean element into the case.
10. Install the element and case into the filter base.
134
Maintenance Section
Every 250 Service Hours or Monthly
Change Water Separator Element
6
3
1
5
4
2
1. Stop the engine. Clean the separator and
surrounding area. Open vent valve (1) and drain valve
(2).
2. Drain the contents of the water separator into a
suitable container. Close the drain and vent valves.
3.
Remove the vent line from retaining bolt (3).
6. Inspect seals (5) and (6). Replace seals if
damaged.
7. Install a new element in the canister. Install the
canister and element assembly and tighten bolt (3) to a
torque of 34 to 41 N•m (25 to 30 lb ft).
4. Loosen retaining bolt (3) and remove canister (4)
and the element. Discard the element.
8.
Connect the vent line to retaining bolt (3).
5.
9.
Prime the fuel system. See Prime the Fuel System.
Wash the canister in clean, nonflammable solvent.
135
Maintenance Section
Every 250 Service Hours or Monthly
Change Secondary Fuel Filter
Prime the Fuel System
After changing the fuel filter(s), prime (purge) the fuel
system to fill filters and remove air bubbles from the
system.
NOTE: DO NOT remove the fitting in the fuel filter
base to release air from the fuel system while priming.
Periodic removal of the fitting will result in increased
wear of the threads in the fuel filter base and lead to
fuel leakage.
1
1. Remove the fuel filter with a strap-type wrench and
discard the filter.
2
2. Clean the filter mounting base. Be sure all of the
old seal is removed.
3. Lubricate the seal of a new filter with clean diesel
fuel.
4. Install the new filter by hand. When the seal
contacts the base, tighten 3/4 of a turn more.
5.
Prime the fuel system. See Prime the Fuel System.
6.
Start the engine and check for leaks.
1. Loosen fuel filter air bleed (1) two full turns. Unlock
and operate priming pump plunger (2) until fuel appears
at the fitting. Use a cloth or container to catch excess
fuel. A considerable amount of pump strokes may be
required to fill filters.
2. Tighten fuel filter air bleed (1) and continue to
operate priming pump plunger (2) until a resistance is
felt. Push the priming pump plunger in and tighten by
hand.
3. Crank the engine promptly after pressurising fuel
system. The engine should start within 15 seconds.
NOTICE
Do not crank the engine continuously for more than 20
seconds. Allow the starter motor to cool for two minutes
before cranking again.
4. If the engine will not start, allow the starter motor
two minutes to cool and repeat Steps 2 and 3.
136
Maintenance Section
Every 250 Service Hours or Monthly
5. If the engine starts, but runs rough, or once started
continues to misfire or smoke, further priming is
necessary to help purge fuel lines of air. Continue to
run engine at low idle until fuel flows free without
pockets of air in the fuel lines and the engine runs
smoothly.
Cooling System (Conventional
Coolant/Antifreeze)
Priming the System if Engine Runs Dry
NOTE: This procedure pertains only to machines
using conventional coolant/antifreeze.
If the engine runs dry, refer to the procedure
Emergency Starting in the Engine Starting section of
the 3176B Engine Operation & Maintenance Manual,
Form No. SEBU6742.
Add Supplemental Coolant Additive/Replace
Element
Refer to the Cooling System Specifications section of
this manual for all cooling system requirements.
To prevent engine damage, never add coolant to an
overheated engine. Allow the engine to cool first.
Use the 8T-5296 Test Kit to check for concentration.
NOTICE
Excessive coolant additive (greater than the recommended
6% initial fill) together with concentrations of antifreeze
greater than 60% cause deposits to form and may result in
radiator tube blockage and overheating.
Add Liquid Supplemental Coolant Additive
(If Required)
1. Loosen the radiator cap slowly to relieve pressure
and remove the cap.
2. It may be necessary to drain enough coolant from
the radiator to allow for the addition of liquid cooling
system additive.
137
Maintenance Section
Every 250 Service Hours or Monthly
3. Add liquid supplemental coolant additive
(conditioner) according to the requirements of your
cooling system as determined by the coolant additive
concentration test.
Differentials and Final Drives
4.
Wipe covers and surfaces around openings before
checking or adding oil. Park on a level surface.
Install the filler cap.
Change Coolant Additive Element
(If Required)
Check Oil Level
NOTE: Perform Steps 1 to 3 to the final drive on each
wheel. Perform steps 4 and 5 to the front and rear
differential.
2
2
1
3
1
1. Close element inlet valve (1) and outlet valve (2).
Remove and discard element (3).
2. Clean the element mounting base. Make sure all of
the old gasket is removed.
1. Position the wheel so final drive drain/level plug (1)
is even with the centre line of the wheel. Remove the
plug.
3. Replace with a new Caterpillar maintenance
element.
2. The oil should be level with the bottom of the
drain/level opening. If necessary add oil through fill
opening (2).
4. Coat the gasket of a new element with a thin film of
engine oil.
3. Clean and install the final drive drain/level and fill
plugs.
5. Install and turn the element until the seal contacts
the base, then tighten 3/4 of a turn more.
6.
Open the inlet and outlet valves.
7.
Remove the radiator cap.
8. Start the engine and check for leaks. Allow the
coolant level to stabilise.
9. Add premixed coolant if necessary to bring the
coolant to within 13 mm (1/2 inch) below the bottom of
the fill pipe or to the proper level on the sight glass.
10. Install the radiator cap.
138
Maintenance Section
Every 250 Service Hours or Monthly
Batteries
Check Electrolyte Level
BATTERY ELECTROLYTE LEVEL
3
Battery
Interval
Conventional
100 Hours
Low Maintenance
250 Hours
Maintenance Free
None Required
Tighten the battery retainers every 1000 hours on all
batteries.
4.
Remove differential fill plug (3).
5. The oil should be level with the bottom of the fill
opening. If necessary, add oil through the fill opening.
Clean and install the differential plug.
Check the following at least every 1000 hours and
more often as conditions require:
•
Clean the top of the batteries with a clean cloth.
•
Keep the terminals clean and coated with petroleum
jelly.
At the proper charging rate, in a moderate climate, a
battery should not require more than 30 cc (1 ounce) of
water per cell per week.
Check the cells weekly in extreme temperatures, cell
water usage could be higher.
1. Open the battery access cover located on the right
hand side at the rear of the machine.
139
Maintenance Section
Every 250 Service Hours or Monthly
Replacement of Battery, Battery Cable or
Disconnect Switch
1. Turn the engine start switch to OFF. Turn all
switches to the OFF position.
2. Turn the battery disconnect switch to OFF and
remove the key.
3.
Open the battery access cover.
4. Disconnect the negative (-) battery cable first,
followed by the other remaining battery cables.
2. Clean the battery surface with a clean cloth. Keep
the terminals clean and coated with petroleum jelly.
Install the post cover after coating.
NOTE: Do not allow the disconnected battery cables
to contact any other terminals apart from the ones that
they were removed from.
3. Inspect the electrolyte level in each battery cell,
except maintenance free. Maintain the level to the
bottom of the fill openings with distilled water. If
distilled water is not available, use clean drinking water.
5. Make the necessary repairs and cable or battery
replacement.
6.
Connect the battery loop and positive (+) cables .
4.
7.
Connect the battery negative (-) cable.
8.
Close the battery access cover.
Close the access cover.
9. Install the key and turn the battery disconnect
switch to ON.
Battery Recycling
1. A battery should always be recycled and never
discarded.
2. A used battery must be returned to a battery dealer
or to an authorised battery collection or recycling
facility.
140
Maintenance Section
Every 250 Service Hours or Monthly
Low Transmission Oil Pressure
Automatic Brake Application (ABA)
System (If Equipped)
4.
Start the engine and raise the bucket slightly.
Test Operation
Certain Elphinstone machines may be equipped with an
optional Automatic Brake Application (ABA) system.
The ABA system warns the operator of an impending
brake application (low transmission oil pressure) and
applies the parking brake if the pressure further
decreases, e.g. engine stalled.
If your machine is equipped with the optional ABA
system, perform the following test to check the system
is functioning correctly.
NOTE: Before testing the operation of the Automatic
Brake Application (ABA) system, test the holding ability
of the machine parking brake. Refer to the topic
Brakes under Every 10 Service Hours or Daily.
1. Be sure the area around the machine is clear of
personnel and obstructions.
2
5. Release the parking brake by moving the control
knob to the OFF position (brakes released).
6.
Shift the transmission to 2nd speed FORWARD.
7. Gradually increase the engine speed to high idle.
The parking brake should remain engaged and the
machine should not move.
NOTE: The parking brake indicator and the fault light
should flash and the action alarm should sound. The
Impending Brake Application (IBA) indicator should be
illuminated.
8. Reduce the engine speed to low idle, move the
transmission control to NEUTRAL and engage the
parking brake. Lower the bucket to the ground and
stop the engine.
NOTICE
1
2. Disconnect hose assembly (1) from tee fitting (2) on
the transmission oil filter assembly.
3. Install a 8S-4950 Cap (9/16-18 JIC) on tee fitting
(2) where the hose was removed.
If the parking brake disengaged and the machine moved
while testing the Automatic Brake Application (ABA)
system, have the system inspected/repaired immediately
before returning the machine to operation. Contact your
Elphinstone dealer or refer to the Braking Section of the
machine Service Manual.
9. Remove the cap from the tee fitting and reconnect
hose assembly (1) to the transmission oil filter
assembly.
141
Maintenance Section
Every 250 Service Hours or Monthly
Cylinder Head Ground Stud
Fan Bearing (R1700-127 to 195)
Inspect/Clean/Tighten
Lubricate the fitting
Wipe all fittings before lubricating.
NOTICE
To avoid seal damage do not over lubricate.
1. Inspect ECM to mounting bolt ground strap,
machine wiring harness ground stud wire and starter to
ground stud negative cable for good connection and
condition.
2. Tighten the grounding stud every oil change. The
cylinder head (grounding stud) may have a wire ground
to battery. Ground wires/straps should be combined at
ground studs dedicated for ground use only.
3. Inspect/check all engine grounds. All grounds
should be tight and free of corrosion.
Check the following at least every other oil change (500
hours), and more often as conditions require:
•
Clean the grounding stud and strap terminals with a
clean cloth.
•
If connections are corroded, clean with a solution of
baking soda and water.
•
Keep the grounding stud and strap clean and coated
with MPGM grease or petroleum jelly.
1.
Lubricate the fitting for the fan bearing.
142
Maintenance Section
Every 250 Service Hours or Monthly
Drive Shaft Universal Joints,
Splines and Bearings
Lubricate Fittings
Wipe all fittings before lubricating.
7
1
2
9
8
6
4. Lubricate one fitting (6) for the front drive shaft
universal joint.
3
4
5
5. Lubricate one fitting in universal joints (7) and (8)
for the centre drive shaft.
6. Fully articulate the machine left or right. Engage
the parking brake and block the wheels. Lubricate one
fitting (9) for the centre drive shaft slip joint spline.
1. Lubricate one fitting in universal joints (1) and (2)
for the upper drive shaft.
2. Lubricate one fitting (3) for the upper drive shaft
slip joint spline.
3. Lubricate one fitting in universal joints (4) and (5)
for the rear drive shaft.
10
7. Lubricate remote mounted fitting (10) for the centre
drive shaft support bearing.
143
Maintenance Section
Every 250 Service Hours or Monthly
Escape Door Pivot Pins (If Equipped)
Air Conditioner (If Equipped)
Lubricate/Check Usability
In the event of an emergency, the enclosed cab escape
door can be opened to gain access to the cab. The
escape door pivot pins must remain serviceable at all
times.
1. Check the escape door pivot pins for wear and
corrosion. Check the cotter pins for serviceability.
Inhaling air conditioner refrigerant gas through a lit
cigarette or other smoking method or inhaling fumes
released from a flame contacting air conditioner
refrigerant gas can cause bodily harm or death. Do
not smoke when servicing air conditioners or
whenever refrigerant gas may be present.
Test Operation - Adjust Belt
1.
Start the engine. Operate the engine at high idle.
2
1
2. Lubricate the fittings for the escape door pivot
pins.
2. Set air conditioner control (1) for maximum cooling
and fan control (2) on HIGH.
3. Allow 2 minutes for the air conditioning system to
stabilise.
144
Maintenance Section
Every 250 Service Hours or Monthly
Air Conditioner Belt Adjustment
3
3
4
2
1
4.
Check for refrigerant in the system as follows:
Feel suction line (3) and discharge line (4).
1.
Loosen compressor bolts (1) and (2).
If the system contains refrigerant, the discharge line
(the smaller hose of the two) will be warmer than the
suction line.
2.
Loosen adjusting bolt (3).
If the system does not contain, or is very low on
refrigerant, poor cooling will result.
5.
Stop the engine to inspect the compressor belt.
3. Move the compressor until the correct belt tension
is reached.
4.
Tighten adjusting bolt (3).
5.
Tighten compressor bolts (1) and (2).
6.
Recheck the belt adjustment.
7.
If necessary, repeat Steps 1 through 5.
8. If poor cooling is still experienced after starting the
engine, turn off the air conditioner. Stop the engine.
Contact your Elphinstone dealer for air conditioner
system service.
6. Inspect the condition and the adjustment of the
compressor belt. The belt should deflect 14 to 20 mm
(.56 to .81 in.) under 110 N (25 lb.) force. Adjust if
necessary.
145
Maintenance Section
Every 250 Service Hours or Monthly
Towing Brake Release System
(If Equipped)
Fire Extinguisher System
(If Equipped)
Lubricate Striker Shaft
Check System
Regular maintenance of the towing brake release
system is necessary to ensure the system functions
correctly when activated. Use a multi-purpose type
grease to lubricate the actuator shaft and prevent
possible seizure of the shaft.
NOTICE
For detailed information on the fire extinguisher system
service procedures, refer to the fire system manufacturer's
service information.
Wipe all fittings before lubricating.
1. Lubricate the fitting for the towing brake release
system actuator shaft.
Perform monthly (250 hour) fire extinguisher system
checks and service procedures in accordance with the
fire system manufacturer's service information.
PB
Maintenance Section
Every 500 Service Hours or 3
Months
Every 500 Service Hours or 3 Months
You must read and understand the warnings
and instructions contained in the Safety Section
of this manual before performing any operation
or maintenance procedures.
Transmission Oil Filter
Change the Filter
5. Clean the filter housing with a clean, nonflammable
solvent.
6.
Clean the housing base.
7. Inspect the filter housing seal. Replace the seal, if
it is damaged.
8.
Insert a new element into the filter housing.
9. Clean and install the filter housing drain plug.
Install the filter housing into the housing base.
10. Start the engine. Apply the service brakes. Use
the right brake pedal only.
11. Release the parking brake and unlock the
transmission neutral lock.
12. Slowly operate the transmission control to
circulate the transmission oil.
13. Move the transmission directional control lever to
NEUTRAL. Engage the transmission lock and apply
the parking brake.
The transmission oil filter is located under the torque
converter access cover.
14. Inspect the transmission filter for leaks.
1.
15. Open the transmission access cover located on
the platform near the operator's station.
Open the upper access cover.
1
2
2. Remove the filter housing drain plug and allow the
oil to drain into a suitable container.
3.
Use a wrench to remove the filter housing.
4.
Remove and discard the used element.
16. Maintain the oil level between the LOW and FULL
marks on dipstick (1). Add oil through fill tube (2) if
necessary.
17. Close the access covers and stop the engine.
147
Maintenance Section
Every 500 Service Hours or 3
Months
Hydraulic Oil System
Change the Filters
4
1
8. Remove hydraulic tank oil filler screen (4). Wash
the screen and the filter covers in clean, nonflammable
solvent.
9.
Install the screen and four new filter elements.
1. Open the hydraulic tank access cover located on
the right hand side of the machine.
2. Relieve the hydraulic tank pressure by pushing on
top of relief valve (1) before changing the filters.
2
3
5
10. Install the covers. Tighten the cover bolts to 56 ±
3 N•m (41 ± 2 lb. ft.).
11. Inspect the filler cap gasket. Replace the gasket if
it is damaged.
3. Remove filter access cover (2) on the hydraulic
tank guard.
4.
Remove the filter covers.
5.
Inspect the cover seals. Replace if necessary.
6.
Remove and discard the four filter elements.
7.
Remove oil filler cap (3).
12. Maintain the hydraulic oil level above the ADD
COLD mark on sight gauge (5) with the engine stopped
and the bucket level on the ground. Add oil if
necessary through the fill tube.
13. Install the oil filler cap.
PB
Maintenance Section
Every 500 Service Hours or 3
Months
Brake Charge Pump Filter
Engine Crankcase Breather
Change the Filter
Clean the Breather
1
1
2
2
The brake charge filter is located on the right hand side
of the rear frame in the engine compartment.
1. Loosen breather outlet hose clamp (1) and remove
the hose from the breather cover.
1. Use a wrench to remove filter housing (2). Remove
the filter element and discard.
2.
2.
Clean the brake charge filter housing.
Loosen retaining bolts (2) and remove the breather.
3. Check the condition of the breather cover gasket.
Replace with a new gasket if the used one is damaged.
3. Inspect the seal in the filter base. If the seal is
damaged, replace it with a new one.
4. Wash the element and cover assembly in a clean,
nonflammable solvent.
4. Install the new element in the housing. Install the
filter housing into the housing base and tighten.
5.
5. Start the engine and run it at low idle. Check for
leaks.
NOTE: The brake charge pump filter should be
changed every 500 Service Hours or 3 Months. This
frequency can be increased if the filter is dirty. The
brake charge pump filter has a contamination warning
indicator on it. Change the filter if indicator (1) is in the
red area when the machine is running.
Shake, or use pressure air to dry the breather.
6. Inspect the hose for damage. Replace if
necessary.
7. Install the breather assembly. Tighten the breather
retainer bolts.
8. Install the hose to the breather and tighten outlet
hose clamp (1).
149
Maintenance Section
Every 500 Service Hours or 3
Months
Fuel Tank Cap and Fill Screen
4.
Clean
5. Install a new filter kit in the cap. Install
components in reverse order.
Wash the cap in a clean, nonflammable solvent.
NOTE: Machines equipped with an optional fast-fill
fuel system do not contain a breather filter element in
the fuel cap. Perform Steps 3 and 5 only on standard
machines without the fast-fill fuel system.
6.
Remove the fill screen from the fill opening.
7. Wash the fill screen in a clean, nonflammable
solvent.
The fuel tank cap is located on the right hand side of
the machine rear frame.
1
5
1
4
2
3
1. Lift and turn lever (5) counterclockwise until it
stops. Lift the cap straight up to remove.
2. Inspect seal (4) for damage. Replace the seal if
necessary.
3. Remove screws (1), filter assembly (2), valve (3)
and gaskets.
8.
Install the fill screen into the fill opening.
9.
Install the fuel cap.
PB
Maintenance Section
Every 500 Service Hours or 3
Months
Fire Extinguisher System
(If Equipped)
Check System
NOTICE
For detailed information on the fire extinguisher system
service procedures, refer to the fire system manufacturer's
service information.
Perform 3 monthly (500 hour) fire extinguisher system
checks and service procedures in accordance with the
fire system manufacturer's service information.
151
Maintenance Section
Every 1000 Service Hours or 6 Months
Every 1000 Service Hours or 6 Months
You must read and understand the warnings
and instructions contained in the Safety Section
of this manual before performing any operation
or maintenance procedures.
Transmission Oil
Change the Oil
1. Operate the engine long enough to warm the oil.
The machine must be level. Lower the bucket with
slight down pressure.
2.
Engage the parking brake. Stop the engine.
6. Remove the magnetic tube assembly from the
screen.
7. Wash the tube assembly and the screen in a clean,
nonflammable solvent.
8. Clean the magnets with a cloth, stiff bristle brush
or pressure air.
2
NOTICE
Do not drop or rap the magnets against any hard objects.
Replace any damaged magnets.
1
9. Clean the cover and inspect the seal. Replace the
seal if it is damaged.
3. Remove the transmission drain plug (1) (obscured).
Install a 1 inch NPT pipe nipple, 100 mm (4 in.) long, to
open the internal drain valve and drain the oil. Drain
the oil into a suitable container.
10. Insert the magnets in the screen.
4. Change the filter element. See the topic
Transmission Oil Filter under Every 500 Service Hours
or 3 Months.
12. Install the cover. Tighten the cover bolts.
5. Remove cover (2) and the magnetic screen tube
assembly from the housing.
11. Insert the screen, tube and magnets in the
housing.
13. Remove the pipe nipple and install the drain plug.
Tighten the drain plug to 68 ± 7 N•m (50 ±5 lb.ft.).
152
Maintenance Section
Every 1000 Service Hours or 6 Months
7
3
2
14. Remove hose (2) from torque converter scavenge
screen assembly (3) and drain the oil into a suitable
container. Remove the screen from the base of the
torque converter housing.
20. Start and run the engine at low idle.
15. Clean and inspect the screen. Inspect the seal on
the fitting. Replace the seal if it is damaged.
22. Apply the service brake and slowly operate the
transmission control to circulate the oil.
16. Install the screen assembly in the housing and
connect the hose.
23. Maintain the oil level to the FULL mark on dipstick
(6). Add oil through fill tube (5) if necessary.
21. Release the parking brake and unlock transmission
neutral lock (7).
24. Move the transmission control lever to NEUTRAL.
Apply the parking brake and lock the transmission
neutral lock (7).
4
25. Stop the engine.
6
5
17. Open the transmission access cover located on
the platform near the operator's station.
18. Remove transmission breather (4). Wash the
breather in clean, nonflammable solvent. Install the
transmission breather.
19. Fill the transmission with oil through fill tube (5).
See the Lubricant Viscosities and Refill Capacities
chart.
26. Close the access cover.
153
Maintenance Section
Every 1000 Service Hours or 6 Months
Differentials and Final Drives
Change the Oil
Wipe covers and surfaces around openings before
checking or adding oil.
4. Remove the front differential fill plug and fill the
differential to the bottom of the fill opening. See the
Lubricant Viscosities and Refill Capacities chart. Clean
and install the fill plug.
1. Position each front wheel with the drain/level plug
down. Remove the drain plugs and allow the oil to
drain into a suitable container.
2
1
5. Position the front wheels so drain/level plug (1) is
even with the centre line of the wheel. Remove the
plug.
2. Remove the front differential drain plug and allow
the oil to drain into a suitable container.
3. Clean and install the differential and final drive drain
plugs.
6. Remove fill plug (2) and fill both front final drives
slowly to the bottom of the level openings. See the
Lubricant Viscosities and Refill Capacities chart. Clean
and install the plugs.
7. Repeat Steps 1 through 6 for the rear differential
and final drives.
154
Maintenance Section
Every 1000 Service Hours or 6 Months
Brake Accumulators
Check Service Brake Accumulator Charge
Pressure
Front Differential Breather Location.
Correct service brake accumulator charge pressure is
necessary for efficient hydraulic brake operation.
Special tools and equipment are required to test the
accumulator.
Rear Differential Breather Location.
8.
Remove the front and rear differential breathers.
NOTE: To access the front differential breather,
remove the cover on the front of the machine.
9. Wash the breathers in clean, nonflammable
solvent.
10. Install the clean breathers.
For the correct testing and charging procedures for the
hydraulic brake accumulator, refer to the Braking
System section of your machine Service Manual, or
contact your Elphinstone dealer.
155
Maintenance Section
Every 1000 Service Hours or 6 Months
Check Park Brake Accumulator Charge
Pressure
Check Auxiliary Accumulator Charge
Pressure
Correct park brake accumulator charge pressure is
necessary for efficient hydraulic brake operation.
Correct auxiliary brake accumulator charge pressure is
necessary for efficient hydraulic brake operation.
Special tools and equipment are required to test the
accumulator.
Special tools and equipment are required to test the
accumulator.
For the correct testing and charging procedures for the
hydraulic brake accumulator, refer to the Braking
System section of your machine Service Manual, or
contact your Elphinstone dealer.
For the correct testing and charging procedures for the
hydraulic brake accumulator, refer to the Braking
System section of your machine Service Manual, or
contact your Elphinstone dealer.
156
Maintenance Section
Every 1000 Service Hours or 6 Months
Ride Control Accumulator
(If Equipped)
Falling Object Protective Structure
(FOPS)
Check Accumulator Charge Pressure
Inspect FOPS/Tighten Bolts
The ride control accumulator, when properly charged,
reduces the fore and aft pitching motion of the
machine.
Check for any loose or damaged bolts. Replace
damaged or missing bolts with original equipment parts
only. See the Torque Specifications chart for correct
tightening torques.
Special tools and equipment are required to test the
accumulator.
For the correct testing and charging procedures for the
ride control accumulator, refer to R1700 Series II
L.H.D. Hydraulic System, Systems Operation, Testing
and Adjusting, Form No. RENR4560 (9EL2024) in the
machine Service Manual or contact your Elphinstone
dealer.
NOTE: Apply thread lubricant to all FOPS bolt threads
before installing. Failure to apply lubricant can result in
improper bolt torque.
Check for damage or cracking of the FOPS. Do not
straighten or repair by welding reinforcement plates to
the FOPS.
Contact your Elphinstone dealer for repair of cracks in
welds, castings or any metal section on the FOPS.
Ensure any certification labels are firmly fixed and
legible.
157
Maintenance Section
Every 1000 Service Hours or 6 Months
Fire Extinguisher System
(If Equipped)
Check System
NOTICE
For detailed information on the fire extinguisher system
service procedures, refer to the fire system manufacturer's
service information.
Perform 6 monthly (1000 hour) fire extinguisher system
checks and service procedures in accordance with the
fire system manufacturer's service information.
158
Maintenance Section
Every 2000 Service Hours or 1 Year
Every 2000 Service Hours or 1 Year
You must read and understand the warnings
and instructions contained in the Safety section
of this manual before performing any operation
or maintenance procedures.
Engine Valve Lash/Unit Injector
Preload
Check/Adjust
Engine Valve Rotators
Check
When inspecting the valve rotators, protective
glasses or face shield and protective clothing must
be worn, to prevent being burned by hot oil spray.
The electronic engine uses high voltage to the unit
fuel injectors. Do not come in contact with the
injector terminals while the engine is running.
Be sure the engine cannot be started while this
maintenance is being performed. To prevent possible
injury, do not use the starter motor to turn the
flywheel.
1.
Remove the engine valve covers.
2.
Start the engine and run at low idle.
Hot engine components can cause burns. Allow
additional time for the engine to cool before checking
valve clearance.
The electronic engine uses high voltage to the unit
fuel injectors. Disconnect injector enable circuit
connector to prevent personal injury. Do not come
into contact with the injector terminals while the
engine is running.
Initial valve lash/unit injector adjustment on new, rebuilt
or remanufactured engines is recommended at the first
oil change (250 hour) interval due to initial wear and
seating of valve train components. All subsequent
adjustments are to be performed at 2000 Hour intervals
thereafter.
The procedures for engine valve lash and unit injector
preload adjustment should be performed according to
the information in the machine Service Manual. Refer
to the Service Manual or your Elphinstone dealer for
the complete valve lash/unit injector adjustment
procedure.
3. Watch the top surface on each valve rotator. Each
valve rotator should turn slightly each time the valve
closes.
If a valve fails to rotate, contact your Caterpillar or
Elphinstone dealer.
159
Maintenance Section
Every 2000 Service Hours or 1 Year
Engine Mounts & Crankshaft
Vibration Damper
Check/Inspect Crankshaft Vibration Damper
Check/Inspect Engine Mounts
Elphinstone recommends inspecting the engine mounts
for deterioration and proper bolt torque. This check
will prevent excessive engine vibration caused from
deterioration and/or improper or worn mounting.
For correct engine mount torque specifications refer to
the machine Service Manual or contact your
Elphinstone dealer.
Damage to, or failure of the damper will increase
torsional vibrations and result in damage to the
crankshaft and other engine components. A
deteriorating vibration damper will cause excessive
gear train noise at variable points in the engine speed
range.
The vibration damper can have visual wobble
(movement to the front and rear when in rotation) on
the outer ring. This does not mean a replacement is
necessary since some wobble of the outer ring is
normal.
The vibration damper has marks on the hub and ring
that indicate the condition of the damper. These marks
can only be viewed if the pulley assembly is removed
from the vibration damper. If the pulley is removed for
any maintenance/repair purposes, check the alignment
marks. If the marks are not in alignment, install a new
vibration damper.
NOTE: Refer to the Service Manual for the necessary
specifications and replacement procedures.
160
Maintenance Section
Every 2000 Service Hours or 1 Year
Hydraulic Tank Oil
Change the Oil
3
Operate the engine long enough to warm the oil.
The machine must be level. Lower the bucket to the
ground with slight down pressure. Engage the parking
brake and stop the engine.
Wipe covers and surfaces around openings before
checking or adding oil.
4. Remove drain plug (3), located in the bottom of the
hydraulic tank.
5. Install a 1 inch NPT pipe nipple, 100 mm (4 in.)
long, to open the internal drain valve and drain the oil.
1
6. Remove the pipe nipple and install the drain plug.
Tighten the drain plug to 68 ± 7 N•m (50 ± 5 lb.ft.).
7. Change the hydraulic system filters. See Hydraulic
Oil System in the Every 500 Service Hours or 3 Months
section.
1. Open the hydraulic tank access cover located on
the upper right hand side of the machine.
2. Relieve the hydraulic tank pressure by pushing on
top of relief valve (1) before removing the oil filler cap.
2
8. Remove the retaining ring and fill screen. Clean
the fill screen in a clean, nonflammable solvent. Shake
or use pressure air to dry.
9.
Install the fill screen and retaining ring.
10. Fill the hydraulic oil tank. See Lubricant Viscosities
and Refill Capacities.
11. Inspect the filler cap gasket. Replace the gasket if
damaged.
12. Install the oil filler cap.
13. Start and run the engine for a few minutes.
3. Remove oil filler cap (2) slowly to relieve any
remaining pressure.
161
Maintenance Section
Every 2000 Service Hours or 1 Year
Hydraulic Tank Vacuum Breaker
2
Clean
4
14. Maintain the oil level above the ADD COLD mark in
sight gauge (4). Add oil through fill tube (2), if
necessary.
NOTE: The oil must be free of bubbles. If bubbles are
present in the oil, air is entering the hydraulic system.
Inspect the suction line hoses and clamps.
1. Open the hydraulic tank access cover located on
the upper right hand side of the machine.
15. Stop the engine.
2.
16. If necessary, tighten any loose clamps and
connections. Replace any damaged hoses.
3. Clean the breaker valve in a clean, nonflammable
solvent. Shake dry or use pressure air.
4.
Remove the hydraulic tank breaker valve.
Install the breaker valve. Close the access cover.
162
Maintenance Section
Every 2000 Service Hours or 1 Year
Wheel Brakes
Towing Brake Release System
(If Equipped)
Check Wheel Brake Wear
Check Operation
Block the wheels securely so that the machine cannot
move prior to activating the towing brake release
mechanism. Failure to do so may result in the
machine moving unexpectedly, causing serious
personal injury or death.
The following test is a two person operation. An
operator must remain in the operator's station for the
duration of the test procedure. The operator must
apply and maintain application of the service brakes
until all other personnel are clear of the machine.
It is necessary to monitor wheel brake wear to maintain
an efficient braking system and prevent unnecessary
wear to brake system components. The wheel brake
disc wear can be checked without having to remove
the wheel brake assembly.
Refer to the Braking System section of your machine
Service Manual for information on checking for brake
disc wear.
Excessive brake wear may result in loss of braking.
Failure to follow this procedure may result in injury
or machine damage.
Perform the following test to check the operation of the
towing brake release system.
1. Move the machine to a level surface and block the
wheels so the machine cannot move. Lower the
bucket to the ground with slight down pressure.
2. Engage the parking brake by moving the parking
brake control knob to the ON position. An operator
must remain in the operator's station to apply and
maintain application of the service brakes.
1
3. Remove protective locking plate (1) from the striker
assembly.
163
Maintenance Section
Every 2000 Service Hours or 1 Year
7. Move the machine back to the level service area.
Manually apply the service brakes, lower the bucket to
the ground and stop the engine. Block the wheels so
the machine can not move.
8. Reset the towing brake release system by moving
striker shaft (2) out and installing cotter pin (3). Inspect
and replace the cotter pin if any signs of damage or
corrosion is evident.
3
2
NOTICE
Always fit the correct part number cotter pin in the striker
shaft. Failure to do so may prevent the towing brake
release system from functioning correctly.
4
2
1
3
9. Install protective locking plate (1) on the striker
shaft. Release the service brakes. The machine is now
ready for operation.
4. Remove cotter pin (3) from striker shaft (2) and
move the striker shaft inwards to activate striker valve
(4). The parking brake should release when the striker
valve is activated.
5. Remove the wheel chocks from the machine.
Raise the bucket off the ground. The operator should
release the service brakes and check that the parking
brake has been released by the towing brake release
system.
6. Move the transmission control lever to 2nd speed
FORWARD. Drive the machine forward on a level
surface for approximately 5 meters. The machine
should be able to be driven freely with the towing brake
release system activated.
NOTICE
If the parking brake remained engaged while testing the
towing brake release system, have the system inspected/
repaired immediately before returning the machine to
operation. Contact your Elphinstone dealer or refer to the
Braking Section of the machine Service Manual.
164
Maintenance Section
Every 2000 Service Hours or 1 Year
Fire Extinguisher System
(If Equipped)
Check System
NOTICE
For detailed information on the fire extinguisher system
service procedures, refer to the fire system manufacturer's
service information.
Perform yearly (2000 hour) fire extinguisher system
checks and service procedures in accordance with the
fire system manufacturer's service information.
165
Maintenance Section
Every 3000 Service Hours or 2 Years
Every 3000 Service Hours or 2
Years
You must read and understand the warnings
and instructions contained in the Safety Section
of this manual before performing any operation
or maintenance procedures.
Cooling System Coolant
(Conventional Coolant/Antifreeze)
Change Coolant/Clean System
NOTE: This procedure pertains to machines using
conventional coolant/antifreeze only.
NOTICE
2. Open the drain valve on the bottom of the radiator
and allow the coolant to drain into a suitable container.
Do not change the coolant until you read and understand
the material in the Cooling System Specifications section.
Drain the coolant whenever the coolant is dirty or
foaming is observed.
NOTICE
Dispose of used engine coolant properly or recycle. Various
methods have been proposed to reclaim used coolant for
reuse in engine cooling systems. The full distillation
procedure is the only method acceptable by Caterpillar to
reclaim the used coolant. Contact your Elphinstone or
Caterpillar dealer for imformation regarding disposal and
recycling of used coolant.
3. Close the drain valve. Fill the system with clean
water and a 6 to 10% concentration of cooling system
cleaner.
4. Start and run the engine for 90 minutes. Stop the
engine and drain the cleaning solution into a suitable
container.
5. Flush the system with clean water, with the engine
stopped, until the draining water is clear.
1.
Remove the radiator cap slowly to relieve pressure.
6.
Close the drain valve.
7. Add the coolant solution. Add coolant slowly to
help avoid air locks, 20 liters (5 U.S. gallons) per
minute. See Cooling System Specifications and Refill
Capacities.
NOTE: Do not add supplemental coolant additive or
change element at this time, unless you are not using
Caterpillar Antifreeze which contains additive.
8. Start and run the engine with the radiator cap
removed, until the thermostat opens and the level
stabilizes. Check for leaks.
166
Maintenance Section
Every 3000 Service Hours or 2 Years
9. Inspect the condition of the radiator cap gasket.
Replace the cap if damaged. If the gasket is not
damaged, use a 9S8140 Service Tool to pressure test
the radiator cap. The correct cap relief pressure is
stamped on the radiator cap or refer to the Engine
Specifications section of your machine Service Manual.
If the radiator cap does not hold the correct pressure,
install a new cap.
Cooling System Coolant
(Extended Life Coolant/Antifreeze)
Add "Extender"
NOTE: This procedure pertains to machines using
Extended Life Coolant/Antifreeze only.
Extender should only be added to ELCA after 3000
Service Hours or 2 Years, which ever comes first. Add
Extender to the coolant to obtain a 2.2 ± 0.3%
Extender concentration.
1.
Stop the engine and allow to cool.
2.
Remove the radiator cap slowly to relieve pressure.
3. The cooling system should be treated with .97 liter
(1 qt) of Extender for every 46 liters (12 US gal) of
cooling system capacity.
4.
10. Maintain the coolant level to within 13 mm (1/2 in)
of the bottom of the fill pipe or to the proper level on
the sight gauge.
11. Install the radiator cap.
12. Stop the engine.
Clean Outside of Radiator Fins
Clean the outside of the radiator fins using compressed
air, high pressure water or steam to remove dust,
leaves and general debris.
The use of compressed air is preferred.
Install the radiator cap.
For more Extender information, refer to the topic
Caterpillar's Extended Life Coolant/Antifreeze in the
Cooling System Specifications section of this manual.
167
Maintenance Section
Every 6000 Service Hours or 4
Years
Every 6000 Service Hours or 4
Years
You must read and understand the warnings
and instructions contained in the Safety Section
of this manual before performing any operation
or maintenance procedures.
Cooling System Coolant
(Extended Life Coolant/Antifreeze)
Clean/Flush/Change Coolant
NOTE: This procedure pertains to machines using
Extended Life Coolant/Antifreeze only.
NOTICE
Do not change the coolant until you read and understand
the material in the Safety and Cooling System Specifications
sections of this manual.
Caterpillar Extended Life Coolant/Antifreeze should be
replaced every 6000 Service Hours or 4 Years,
whichever comes first. Only clean water is needed to
clean and flush the cooling system when ELCA is
drained and replaced.
Drain
1. Stop the engine and allow to cool. Loosen the
radiator cap slowly to relieve pressure and remove the
cap.
2. Open the drain valve. Remove the block and oil
cooler drain plugs. Remove the drain plug from the
bottom of the water pump housing. Allow the coolant
to drain into a suitable container.
NOTICE
Dispose of used engine coolant properly or recycle. Various
methods have been proposed to reclaim used coolant for
reuse in engine cooling systems. The full distillation
procedure is the only method acceptable by Caterpillar to
reclaim the used coolant. Contact your Elphinstone or
Caterpillar dealer for information regarding disposal and
recycling of used coolant.
Flush
3. Flush the cooling system with clean water to
remove any debris.
4. Clean and install all drain plugs and close the drain
valve.
5. Fill the system with clean water. Install the radiator
cap. Operate the engine until warm, 49 to 66°C (120
to 150°F).
6. Stop the engine and allow to cool. Loosen the
radiator cap slowly to relieve pressure and remove the
cap. Open the drain valve and allow the water to drain.
Flush the cooling system with clean water until the
draining water is clear.
7.
Close the drain valve.
Fill
8. Fill the cooling system with ELCA. Add coolant
slowly to avoid air locks, 20 liters (5 US gal) per minute.
Refer to the Refill Capacities chart in this manual for the
amount of ELCA needed to refill your system.
9. Start and run the engine with the radiator cap
removed. Allow the ELCA to warm, the thermostat to
open and the coolant level to stabilise. Add ELCA if
necessary to bring the coolant to the proper level.
10. Inspect the condition of the radiator cap gasket.
Replace the cap if damaged. If the gasket is not
damaged, use a 9S8140 Service Tool to pressure test
the radiator cap. The correct cap relief pressure is
stamped on the radiator cap or refer to the Engine
Specifications section of your machine Service Manual.
If the radiator cap does not hold the correct pressure,
install a new cap.
11. Start the engine and inspect for coolant leaks and
proper operating temperature.