Caterpillar 426

MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt

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SEBU7267 September 1999

Operation and Maintenance Manual 416C, 426C, 428C, 436C and 438C Backhoe Loaders 5YN16590-Up (Machine) 7WN1100-Up (Machine) 8RN4990-Up (Machine) 9JN1050-Up (Machine) 9KN1400-Up (Machine) 1ER900-Up (Machine) 1GR950-Up (Machine) 1JR1150-Up (Machine) 1NR1050-Up (Machine) 1RR1100-Up (Machine) 1TR1850-Up (Machine) 1XR2250-Up (Machine) 1ZR1000-Up (Machine) 2BR1000-Up (Machine) 2CR19310-Up (Machine) 2DR3450-Up (Machine)















188 Maintenance Section Maintenance Interval Schedule

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Maintenance Interval Schedule SMCS Code: 7000 Note: All safety information, warnings, and instructions must be read and understood before you perform any operation or any maintenance procedure. Before each consecutive interval is performed, all of the maintenance requirements from the previous interval must also be performed. The normal oil change interval is Every 500 Service Hours or Three Months. If the engine is operated under severe conditions or if the oil is not Caterpillar oil, change the oil after Every 250 Service Hours or after One Month. Severe conditions include the following factors: high temperatures, continuous high loads, and extremely dusty conditions. Refer to the results of the S·O·S oil analysis in order to determine if the oil change interval should be decreased to 250 hours. Consult your Caterpillar Dealer for detailed information regarding the optimum oil change interval.

Note: Certain machines are equipped with engines that require the engine valve lash to be checked every 1000 service hours or 6 months. Refer to the Operation and Maintenance Manual, “Engine Valve Lash - Check” for further information.

When Required Air Conditioner - Test .......................................... 190 Battery - Recycle ................................................ 192 Battery Electrolyte Level - Check ........................ 192 Battery or Battery Cable - Replace ..................... 192 Bucket Cutting Edges - Inspect/Replace ............ 194 Bucket Tips - Inspect/Replace ............................ 195 Engine Air Filter Primary Element Clean/Replace .................... ............................... ..................... ................... ......... 205 Engine Air Filter Secondary Secondary Element - Replace .. 206 Fuel System - Prime ........................................... 213 Fuses - Replace .................... ............................... ..................... ................... ......... 216 Oil Filter - Inspect ................................................ 222 Radiator Core - Clean ......................................... 223 Window Wipers - Inspect/Replace ...................... 234

Every 10 Service Hours or Daily

Engine Oil Level - Check .................... .............................. ................ ...... 208 Extendable Stick Pads - Inspect/Replace ........... 210 Fuel System Water Separator - Drain ................. 214 Hydraulic System Oil Level - Check .................... 220 Kingpin Bearings (Front) - Lubricate ................... 220 Loader Bucket, Cylinder, and Linkage Bearings Lubricate .................... .............................. ..................... ..................... .................. ........ 221 Seat Belt - Inspect ..................... ............................... .................... ............... ..... 224 Secondary Steering Test .................... .............................. ................ ...... 225 Stabilizer and Cylinder Bearings - Lubricate ....... 225 Swing Swing Frame rame and Cylind Cylinder er Bearing Bearings s - Lub Lubrica ricate te .. 226 Tire Inflation - Check ............................ ...................................... ............... ..... 226 Transmission Oil Level - Check ........................... 229 Walk-Around Walk-Around Inspection ........................... ..................................... ............ 232 Wheel Nut Torque - Check .................................. 233 Windows - Clean ........................ .................................. ..................... ............... .... 234

Every 50 Service Hours or Weekly Axle Universal Joint (Front) - Lubricate ............... ............... 190 Cab Air Filter - Clean/Replace ............................ 195 Fuel Tank Tank Water and Sediment - Drain ............... 215 Parking Brake - Check/Adjust ............................. 222

Every 250 Service Hours or Monthly Axle Universal Joint (Rear) - Lubricate ............... 190 Cooling Cooling System System Coolant Coolant Additive Additive (DEAC) (DEAC) - Add .. 199 Differential Oil Level (Front) - Check ................... 203 Differential Oil Level Level (Rear) - Check ................... ................... 204 Engine Oil and Filter - Change ........................... 208 Final Drive Oil Level (Front) - Check ................... 212 Final Drive Oil Level (Rear) - Check ................... 212 Kingpin Bearings (Rear) - Lubricate ................... 220 Sideshift Stabilizer Wear Pads - Inspect ............. 225 V-Belts - Inspect/Adjust/Replace ........................ 230

Every 500 Service Hours or 3 Months Drive Shaft Spline - Lubricate ............................. 204 Engine Oil and Filter - Change ........................... 208 Fuel System Filter - Replace .............................. 213 Fuel System Water Separator Element Replace ..................... ............................... .................... .................... .................... .......... 215 Hydraulic System Oil Filter - Replace ................. 219 Transmission Oil Filter - Replace ........................ 229

Every 500 Service Hours or 3 Months for Machines Used in Severe (50% or more of loader work) Applications Applications Differential Oil (Rear) - Change .......................... 203















189 Maintenance Section Maintenance Interval Schedule

Transmission Magnetic Screen - Clean .............. 226 Transmission Oil - Change ..................... ............................... ............. ... 227 Wheel Bearings (Front) - Lubricate ..................... 233

Every 2000 Service Hours or 1 Year Engine Valve Lash - Check ................................. 210 Hydraulic System Oil - Change ........................... 217

Every 3000 Service Hours or 2 Years Cooling System Coolant (DEAC) - Change ........ 196 Cooling System System Coolant Extender Extender (ELC) - Add .. 200 Cooling System Water Temperature Regulator Clean/Replace .................... ............................... ..................... ................... ......... 201

Every 6000 Service Hours or 4 Years Cooling System Coolant (ELC) - Change ........... 198















190 Maintenance Section Air Conditioner - Test

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Air Conditioner - Test (If Equipped) SMCS Code: 7320 NOTICE Refrigerant in the air conditioner system can cause personal injury. Avoid any contact with refrigerant. Check the refrigerant before warm weather begins. Check the refrigerant when the system does not work properly. The system should be checked with pressure gauges by a qualified technician. Consult your Caterpillar dealer for proper installation when the system needs refrigerant. Operate the air conditioner at least monthly in order to lubricate the compressor seals. Set the controls on MAXIMUM for 15 minutes. i00595214

Axle Universal Joint (Front) Lubricate

Illustration 266

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Apply lubricant to the grease fittings for the drive shaft to the final drives. There are two grease fittings for each drive shaft. i00613528

Axle Universal Joint (Rear) Lubricate (All Wheel Steer Machines Only) SMCS Code: 3251

SMCS Code: 3251

Illustration 267 Illustration 265

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g00287245















191 Maintenance Section Backhoe Boom, Stick, Bucket, and Cylinder Bearings - Lubricate

Apply lubricant lubricant to the grease fittings for the universal universal joints of each drive shaft to the final drives. There are two grease fittings for each universal joint. i01179717

Backhoe Boom, Stick, Bucket, and Cylinder Bearings Lubricate SMCS Code: 6501; 6502; 6503; 6510; 6511; 6512; 6513; 6533 Illustration 271

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Apply lubricant to the grease fitting (4) for the head end of the stick cylinder. Apply lubricant to the grease fitting (5) for the rod end of the stick cylinder. Apply lubricant to the grease fitting (6) for the pivot pin for the stick. Apply lubricant to the grease fitting (7) for the head end of the bucket cylinder. Apply lubricant to the grease fitting (8) for the rod end of the bucket cylinder. Illustration 269

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Position the backhoe into the service position.

Apply lubricant to the grease fitting (9) for the top of the link. Apply lubricant to the grease fitting (10) for the bottom of the link. Apply lubricant to the grease fitting (11) for the pivot pin. Apply lubricant to the grease fitting (12) for the bucket pivot pin. i00080741

Backup Alarm - Test SMCS Code: 7406 Illustration 270

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Apply lubricant to the grease fitting (1) for the head end of the boom cylinder. Apply lubricant to the grease fitting (2) for the rod end of the boom

Turn the engine start switch key to ON in order to perform the test. Apply the service brake. Move the transmission

















192 Maintenance Section Battery - Recycle

i01176086

Battery - Recycle SMCS Code: 1401 1. Always recycle a battery. Never discard a battery. 2. Always return used batteries to one of the following locations.

• A battery supplier • An authorized battery collection facility • Recycling facility

Illustration 272

i00588592

Battery Electrolyte Level Check SMCS Code: 1401 Table 119

THE TABLE FOR THE BATTERY ELECTROLYTE Battery

Interval

Conventional

100 Hours

Low Maintenance

250 Hours

Mai Mainten ntenan ance ce Free ree

Main Mainte ten nance ance Free ree

Tighten the battery retainers on all of the machines. Tighten the battery retainers at every 1000 hours. Check the following items at every 1000 hours. If necessary, check the following items more often.

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1. Open the battery access cover that is located on the right side of the machine. 2. Clean the battery surface with a clean cloth. Keep the terminals clean and keep the terminals coated with petroleum jelly. Install the post cover after you coat the post with petroleum jelly. 3. Inspect the electrolyte level in each battery cell. A maintenance free battery does not require inspection. Maintain the electrolyte level to the bottom of the filler openings. Use distilled water. If distilled water is not available, use clean drinking water. 4. Close the battery access cover. i00596682

Battery or Battery Cable Replace

















193 Maintenance Section Brake Reservoir Oil Level - Check

7. Install the engine start switch key. i00667135

Brake Reservoir Oil Level Check SMCS Code: 4291-535

Maintain the oil level between the “MIN” mark and “MAX” mark on the brake reservoir. Add oil, if necessary. i00651426

Braking System - Test SMCS Code: 4251; 4267; 7000

Service Brake Holding Ability Test Check the area around the machine. Make sure that the machine is clear of personnel and clear of obstacles. Test the brakes on a dry, level surface. Fasten the seat belt before you test the brakes.

Illustration 273

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The following tests are used to determine if the service brake is functional. These tests are not intended to measure the maximum brake holding effort. The brake holding effort that is required to sustain a machine at a specific engine rpm varies depending on the machine. The variations are the differences in the engine setting, in the power train efficiency, and in the brake holding ability, etc.

1. Start the engine. Raise the bucket slightly. 2. Apply the service brake. Release the parking brake. 3. Move the transmission control lever to THIRD SPEED FORWARD.

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

















194 Maintenance Section Bucket Cutting Edges - Inspect/Replace

Secondary Brake Holding Ability Test Check the area around the machine. Make sure that the machine is clear of personnel and clear of obstacles.

i00058453

Bucket Cutting Edges Inspect/Replace SMCS Code: 6801

Test the brakes on a dry, level surface. Fasten the seat belt before you test the brakes. The following tests are used to determine if the parking brake is functional. These tests are not intended to measure the maximum brake holding effort. The brake holding effort that is required to sustain a machine at a specific engine rpm varies depending on the machine. The variations are the differences in the engine setting, in the power train efficiency, and in the brake holding ability, etc.

1. Start the engine. Raise the bucket slightly. 2. Engage the parking brake. 3. Move the transmission control lever to THIRD SPEED FORWARD.

Personal injury or death can result from bucket falling. Block the bucket before changing bucket cutting edges. 1. Raise the bucket. Place a block under the bucket. 2. Lower the bucket to the blocking. Do not block up the bucket too high. Block up the bucket so that the bucket is high enough to remove the cutting edges and the end bits.

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

Note: The parking brake indicator light should come on and the parking brake alarm should sound.

4. Clean the contact surfaces.

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

5. Use the opposite side of the cutting edge, if this side is not worn. 6. Install a new cutting edge, if both edges are worn.

If the machine begins to move, reduce the engine speed immediately immediately and apply apply the service brake pedal.

7. Install the bolts. Tighten the bolts to the specified torque. Refer to Operation and Maintenance Manual, “Torques for Ground Engaging Tool Bolts”.

















195 Maintenance Section Bucket Tips - Inspect/Replace

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Bucket Tips - Inspect/Replace SMCS Code: 6805

Block Block the buck bucket et before before changi changing ng the buck bucket et teeth. To prevent possible injury to the eyes, wear a protective tective face shield when striking striking the pin. The pin, when struck, can fly out and cause injury to nearby personnel. 1. Drive the pin out of the bucket tip from the retainer side of the bucket tip. Remove the bucket tip and the retainer. 2. Clean the adapter, the pin, and the retainer. Replace any damaged parts. Install the retainer in the groove. 3. The bucket tip should be installed over the retainer. Install the bucket tip in the runner position or in the digger position. 4. Drive the pin through the retainer, through the adapter, and through the bucket tip from the side that is opposite the retainer. i00621342

Cab Air Filter Filter - Clea Clean/Rep n/Replace lace SMCS Code: 7311; 7342

Illustration 276

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1. Remove the filter cover that is located at the bottom of the right hand console. 2. Remove the filter element. 3. Clean the filter element with compressed air or pressure water. Direct the air or the water along the pleats of the element. You can also wash the element with clean water and nonsudsing household detergent. 4. Rinse the filter element thoroughly with clear water. 5. Allow the filter element to air dry. Inspect the element for damage. If the filter element is damaged, replace the filter element. 6. Install the filter element. 7. Install the filter cover.

















196 Maintenance Section Cooling System Coolant (DEAC) - Change

Illustration 278

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Illustration 280

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9. Remove the filter element.

16. Remove the filter element.

10. Clean the filter element with compressed air or pressure water. Direct the air or the water along the pleats of the element. You can also wash the element with clean water and nonsudsing household detergent.

17. Clean the filter element with compressed air or pressure water. Direct the air or the water along the pleats of the element. You can also wash the element with clean water and nonsudsing household detergent.

11. Rinse the filter element thoroughly with clear water.

18. Rinse the filter element thoroughly with clear water.

12. Allow the filter element to air dry. Inspect the element for damage. If the filter element is damaged, replace the filter element.

19. Allow the filter element to air dry. Inspect the element for damage. If the filter element is damaged, replace the filter element.

13. Install the filter element.

20. Install the filter element.

14. Install the filter cover.

21. Close the door. i00598002

Cooling System Coolant (DEAC) - Change



















197 Maintenance Section Cooling Cooling System System Coolant Coolant (DEAC) (DEAC) - Change Change

NOTICE Do not change the coolant until you read and understand the material in the Cooling System Specifications section. 1. Empty the bucket. Remove the pin that secures the loader lift arm brace to the left loader lift arm. Raise the loader arm to the maximum height. 2. Position the loader lift arm brace over the left lift cylinder rod with the flat end against the cylinder end. 3. Push the pin through the holes of the loader lift arm brace and install the cotter pin. 4. Slowly lower the loader arms until the loader lift arm brace contacts the top of the lift cylinder and the bosses on the loader arm. Drain the coolant whenever the coolant is dirty or whenever foaming is observed. The radiator cap is located under the access panel on the top of the engine compartment.

Illustration 283

g00287415

2. Slowly loosen the radiator cap in order to relieve system pressure. Remove the radiator cap.



















198 Maintenance Section Cooling System Coolant (ELC) - Change

Note: If you are using Caterpillar antifreeze, do not add the supplemental coolant additive at this time and/or change the element at this time. 10. Start the engine. Run the engine without the radiator cap until the thermostat opens and the coolant level stabilizes. 11. Maintain the coolant level within 13 mm (0.5 inch) of the bottom of the filler pipe. 12. Install the radiator cap. Replace the radiator cap if the gasket is damaged. Illustration 286

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13. Stop the engine. 14. Replace the access panel. Close the access door. i00095660

Cooling System Coolant (ELC) - Change SMCS Code: 1353; 1395



















199 Maintenance Section Cooling System Coolant Additive (DEAC) - Add

Flushing the Extended Life Coolant From the Cooling System

Liquid Supplemental Coolant Additive

Some engines utilize Extended Life Coolant. See the Operation Operation and Maintenance Maintenance Manual, “Maintenance “Maintenance Interval Schedule” in order to determine the service interval. If a Extended Life Coolant was previously used, flush the cooling system with clean water. No other cleaning agents are required.

Flushing Flushing a Standard Standard Coolant From the Cooling System If you change the coolant of a machine to Extended Life Coolant from another type of coolant, use a Caterpillar cleaning agent to flush the cooling system. After you drain the cooling system, thoroughly flush the cooling system with clean water. All of the cleaning agent must be removed from the cooling system. system.

Note: See the Operation and Maintenance Manual, “Cooling System Coolant (DEAC) - Change” for the draining procedure and for the flushing procedure. i00599502

Illustration 288

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

4. Add 0.24 Liters (.50 pint) of cooling system additive for every 38 Liters (10 US Gallons) of engine cooling capacity.

For additional information on the addition of extender extender,, see Operation Operation and Maintenance Maintenance Manual, Manual, “Caterpillar “Caterpillar Coolant Coolant Recommendati Recommendations” ons” or consult consult your Caterpillar dealer. i00599514

Cooling System Level - Check SMCS Code: 1353; 1395

Illustration 291

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5. Maintain the coolant level within 13 mm (0.5 inch) from the bottom of the filler tube. 6. Install the radiator cap. Close the access door. i00095664

Cooling System Coolant

Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure.



















201 Maintenance Section Cooling System Water Temperature Regulator - Clean/Replace

The thermostat should be replaced after the cooling system has been cleaned. Replace the thermostat while the cooling system is completely drained or while the cooling system coolant is drained to a level that is below the thermostat housing.

Note: If you are only replacing the thermostat, drain the cooling system coolant to a level that is below the thermostat housing. Caterpillar engines incorporate a shunt design cooling system. It is mandatory to always operate the engine with a thermostat. Illustration 294

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1. The radiator cap is located on the top of the radiator on the left side of the machine. Remove the radiator cap slowly in order to relieve system pressure.

1. Empty the bucket. Remove the pin that secures the loader lift arm brace to the left loader lift arm. Raise the loader arm to the maximum height. 2. Position the loader lift arm brace over the left lift cylinder rod with the flat end against the cylinder end. 3. Push the pin through the holes of the loader lift arm brace and install the cotter pin. 4. Slowly lower the loader arms until the loader lift arm brace contacts the top of the lift cylinder and the bosses on the loader arm.





















202 Maintenance Section Differential Oil (Front) - Change

i00601036

Differen Differential tial Oil (Front) (Front) - Change SMCS Code: 3258

Illustration 297

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203 Maintenance Section Differential Oil (Rear) - Change

i00601241

Differential Oil (Rear) - Change SMCS Code: 3258

Rear Axle

Rear Axle with All Wheel Steer (AWS)





















204 Maintenance Section Differential Oil Level (Rear) - Check

Illustration 304

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Illustration 306

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205 Maintenance Section Engine Air Filter Filter Primary Element - Clean/Repla Clean/Replace ce

Illustration 308

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Illustration 310

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206 Maintenance Section Engine Air Filter Secondary Element - Replace

When you use pressure air, the maximum air pressure is 205 kPa (30 psi). When you use pressure water, the maximum water pressure is 280 kPa (40 psi).

i00606478

Engine Air Filter Secondary Element - Replace SMCS Code: 1051; 1054 NOTICE Always replace the secondary secondary filter element. Never attempt to reuse it by cleaning. The second secondary ary filter filter elemen elementt should should be replac replaced ed at the time the primary element is serviced for the third time. The secondary filter element should also be replaced if the yellow yellow piston in the filter element indicator enters























207 Maintenance Section Engine Air Filter Service Indicator Indicator - Inspect Inspect

7. Uncover the air inlet opening. Install a new secondary element. 8. Install the primary element and the air cleaner housi Faste the clips in order to secure





















208 Maintenance Section Engine Oil Level - Check

Engine Oil Level - Check

2. While the engine is stopped, maintain the oil level between the “ADD” mark and the “FULL” mark on the engine oil dipstick (3).

SMCS Code: 1302; 1318; 1326

3. If necessary, remove the oil filler cap (4) and

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209 Maintenance Section Engine Oil and Filter - Change





















210 Maintenance Section Engine Valve Lash - Check

10. Stop the engine and allow the oil to drain back into the oil pan. Maintain the oil level in the crosshatched region of the engine oil dipstick (3). Add oil, if necessary.

i01184251

Extendable Stick Pads Inspect/Replace





















211 Maintenance Section Final Drive Oil (Front) - Change

Note: Place the bucket on the ground. Apply slight pressure toward the ground with the stick. Shim the lower pad or replace the lower pad.































































































































































































































































































Caterpillar 426

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