MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt © 2010 Caterpillar All Rights Reserved ® ®
SEBU6652-01 April 1997 Operation and Maintenance Manual 446B Backhoe Loader 5BL1-Up (Machine)
100 Maintenance Section Maintenance Interval Schedule i00090069 Parking Brake - Check/Adjust ............................. 126 Maintenance Interval Schedule Every 100 Service Hours or 2 Weeks SMCS Code: 7000 Engine Oil and Filter - Change ........................... 127 Note: All safety information, warnings, and instructions must be read and understood before you perform any operation or any maintenance procedure.
101 Maintenance Section Maintenance Interval Schedule Every 6000 Service Hours or 4 Years Cooling System Coolant (ELC) - Change ...........
102 Maintenance Section Battery - Recycle i00037658 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.
103 Maintenance Section Battery or Battery Cable - Replace 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. i00080792 Battery or Battery Cable Replace SMCS Code: 1401 1. Turn the engine start switch to the OFF position. Turn all switches to the OFF position.
104 Maintenance Section Bucket Cutting Edges - Inspect/Replace i00058453 Bucket Cutting Edges Inspect/Replace i00081131 Bucket Tips - Inspect/Replace SMCS Code: 6805 SMCS Code: 6801 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.
105 Maintenance Section Ether Starting Aid Cylinder - Replace i00081566 Ether Starting Aid Cylinder Replace i00081584 Fuel System - Prime SMCS Code: 1258 SMCS Code: 1456; 7528 Illustration 158 Illustration 156 g00104955 1. Remove the engine access panel on the right side of the machine. g00105139 1. Unlock the priming pump plunger and operate the pump. 2. Operate the pump and listen for the fuel to flow into the fuel tank. Close the pump and lock the priming pump plunger. 3.
106 Maintenance Section Fuel Tank Cap and Strainer - Clean i00081586 Fuel Tank Cap and Strainer Clean i00089307 Fuses - Replace SMCS Code: 1417 SMCS Code: 1273 Illustration 161 Illustration 159 g00107649 g00105168 The fuel tank cap is located on the left side of the machine. Move the latch and open the panel cover in order to access the fuse panel. Fuses – Fuses protect the electrical system from damage that is caused by overloaded circuits. Replace the fuse if the element separates.
7 Maintenance Section Oil Filter - Inspect Horn and Return to Dig (5) – 10 Amp i00052234 Rotating Beacon (6) – 10 Amp Oil Filter - Inspect Left Turn Signal (7) – 10 Amp SMCS Code: 1318; 3067; 5068 Rear Windshield Wiper (8) – 15 Amp Inspect A Used Filter for Debris Gauges (9) – 10 Amp Instrument Panel Lights (10) – 10 Amp Key Switch (11) – 15 Amp Spare (12) – Open Front Work Lights (13) – 10 Amp Rear Work Lights (14) – 20 Amp Hazard Flashers (15) – 15 Amp Blowers (16) – 20 Amp Illustration 163 g
108 Maintenance Section Radiator Core - Clean i00094900 Radiator Core - Clean i00058886 Windshield Wipers Inspect/Replace SMCS Code: 1353 SMCS Code: 7305 Inspect the condition of the windshield wiper blades. Replace the windshield wiper blades if the windshield wiper blades are worn or damaged. If the windshield wiper blades streak the windshield, replace the windshield wiper blades . Illustration 164 g00105056 1. Remove both of the engine access panels in order to access the radiator core.
109 Maintenance Section Axle Oscillation Bearings - Lubricate i00079835 Axle Oscillation Bearings Lubricate SMCS Code: 3278; 3282 i00079849 Backhoe Boom, Stick, Bucket, and Cylinder Bearings Lubricate SMCS Code: 6501; 6502; 6503; 6510; 6511; 6512; 6513; 6533 Illustration 167 g00104961 Illustration 169 g00104983 Position the backhoe into the service position. Illustration 168 g00104960 Apply lubricant to the two remote grease fittings for the trunnion bearings.
110 Maintenance Section Backup Alarm - Test i00080741 Backup Alarm - Test SMCS Code: 7406 Turn the engine start switch key to ON in order to perform the test. Apply the service brake. Move the transmission direction control lever to REVERSE position. Illustration 171 g00104963 Apply lubricant to the grease fitting for the head end of the stick cylinder (4). Apply lubricant to the grease fitting for the rod end of the stick cylinder (5).
111 Maintenance Section Braking System - Test i00080882 Braking System - Test SMCS Code: 4251; 4267 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. 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.
112 Maintenance Section Cooling System Level - Check i00081340 Cooling System Level - Check SMCS Code: 1353; 1395 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. Illustration 172 g00105008 Open the access panel on the top of the engine compartment. Illustration 173 g00105009 1. The radiator cap is located on the top of the radiator on the left side of the machine.
113 Maintenance Section Engine Air Filter Primary Element - Clean/Replace i00081499 3. Clean the primary filter element. Engine Air Filter Primary Element - Clean/Replace The filter elements can be cleaned by using the following methods: SMCS Code: 1051; 1054 • pressure air NOTICE Never service the air cleaner when the engine is running, to avoid engine damage. • pressure water • detergent washing When you use pressure air, the maximum air pressure is 205 kPa (30 psi).
114 Maintenance Section Engine Air Filter Secondary Element - Replace i00081511 Engine Air Filter Secondary Element - Replace SMCS Code: 1051; 1054 NOTICE Always replace the secondary filter element. Never attempt to reuse it by cleaning. The secondary filter element should be replaced at the time the primary element is serviced for the third time.
115 Maintenance Section Engine Air Filter Service Indicator - Inspect i00081512 Engine Air Filter Service Indicator - Inspect SMCS Code: 1051; 1054; 7452 NOTICE Service the air cleaner only with the engine stopped. Engine damage could result. Illustration 181 g00105046 9. Reset the filter element indicator. 10. Replace the engine access panel. Illustration 182 g00105046 The filter service indicator is located on the left side of the dashboard in the cab. Start the engine.
116 Maintenance Section Engine Air Precleaner - Clean i00081521 i00081535 Engine Air Precleaner - Clean Engine Oil Level - Check SMCS Code: 1055 SMCS Code: 1302; 1318; 1326 NOTICE Do not overfill the crankcase. Engine damage can result. Illustration 183 g00105063 1. Empty the precleaner bowl whenever the dirt reaches the “FULL” mark. Illustration 185 g00105081 1. Open the engine access door on the left side of the machine. Illustration 184 g00105066 2.
117 Maintenance Section Hydraulic System Oil Level - Check i00091385 Hydraulic System Oil Level Check SMCS Code: 5056; 7479 Illustration 189 g00106775 Open the access cover on the top of the engine compartment. Remove the cap in order to add hydraulic oil, if necessary. Illustration 187 g00106776 The sight gauge for the hydraulic tank is located on the left side of the machine. Move the backhoe to the transport position and lower the loader bucket to the ground. Turn off the engine.
118 Maintenance Section Loader Bucket, Cylinder, and Linkage Bearings - Lubricate i00091415 Loader Bucket, Cylinder, and Linkage Bearings - Lubricate SMCS Code: 7069; 7070; 7071 Illustration 190 g00106902 Apply lubricant to the grease fitting for the upper pivot pin (1). Apply lubricant to the grease fittings for the lower pivot pins (2). Apply lubricant to the grease fitting for the rod end of the tilt cylinder (3).
119 Maintenance Section Seat Belt - Inspect i00317205 Seat Belt - Inspect Secondary Steering Test (If Equipped) SMCS Code: 7327 Always check the condition of the seat belt and the condition of the mounting hardware before you operate the machine. Replace any parts that are damaged or worn. Regardless of the appearance of the seat belt, the seat belt should be replaced at every three year interval. A date label is attached to each seat belt. Use this label in order to determine the age of the seat belt.
120 Maintenance Section Stabilizer and Cylinder Bearings - Lubricate i00094916 i00095009 Stabilizer and Cylinder Bearings - Lubricate Swing Frame and Cylinder Bearings - Lubricate SMCS Code: 5468; 7222 SMCS Code: 5105; 6506; 6507; 7063 Illustration 194 g00107005 Position the stabilizer, as shown. Apply lubricant to the grease fittings at each end of the cylinder (1). Apply lubricant to the grease fitting for the pivot of the stabilizer (2). Repeat for the other stabilizer.
121 Maintenance Section Tire Inflation - Check i00095063 i00095361 Tire Inflation - Check Transmission Oil Level - Check SMCS Code: 4203 SMCS Code: 3030; 3080; 3081 Check the transmission oil level while the machine is on a level surface. Illustration 196 g00107022 Measure the tire pressure on each tire. Consult your Caterpillar dealer for the correct load rating and for the correct operating pressures. Inflate the tires, if necessary. See Operation and Maintenance Manual, “Tire Inflation”.
122 Maintenance Section Walk-Around Inspection i00095415 Walk-Around Inspection SMCS Code: 7000 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: Inspect the machine for leaks. If leaks are observed, find the source of the leak and correct the leak.
123 Maintenance Section Wheel Nut Torque - Check i00095438 i00095456 Wheel Nut Torque - Check Windows - Clean SMCS Code: 4051; 4199; 4200 SMCS Code: 7310; 7340 Illustration 200 g00107226 Check the torque on new wheels or repaired wheels after every ten service hours until the specified torque is maintained. Torque the nuts to 440 ± 40 N·m (325 ± 30 lb ft). Check the nuts on all four wheels.
124 Maintenance Section Axle Universal Joint (Front) - Lubricate i00119137 Axle Universal Joint (Front) Lubricate SMCS Code: 3251 i00081140 Cab Air Filter - Clean/Replace SMCS Code: 7311; 7342 Clean Filters NOTICE Do not clean the elements by bumping or tapping them. Inspect the elements after cleaning. Do not use an element with damaged pleats, gaskets or seals. When cleaning with pressure air, use 205 kPa (30 psi) maximum to prevent element damage by too much air pressure.
125 Maintenance Section Cab Air Filter - Clean/Replace 1. Open the access panel on the top of the engine compartment. Illustration 208 Illustration 206 g00105001 g00105003 1. Remove the recirculation filter for the cab. The filter element is located under the dashboard. 2. Remove the filter element and clean the filter element with compressed air or with pressure water. You can also wash the filter element with a solution of warm water and of a nonsudsing household detergent. 2.
126 Maintenance Section Kingpin Bearings - Lubricate i00091394 i00095642 Kingpin Bearings - Lubricate Parking Brake - Check/Adjust SMCS Code: 4314 SMCS Code: 4267 Illustration 209 g00106819 Fitting for the upper kingpin bearing Illustration 210 g00106820 Fitting for the lower kingpin bearing Apply lubricant to the four grease fittings for the kingpin bearings. There are two grease fittings for the left side and two grease fittings for the right side.
127 Maintenance Section Engine Oil and Filter - Change 4. Back off the modulating body (4) to the first flat and tighten the locking bolt (3). 5. Install the caliper lever (2) so that the top of the lever is flush with the bottom of the mounting bracket (6) and the top of the lever is pointing to the left of the machine. 6. Install the rod (1). 7. Verify that the fully released position at the parking brake handle produces a fully released condition at the caliper.
128 Maintenance Section Engine Oil and Filter - Change Illustration 214 g00105086 3. Remove the filter element with a strap type wrench. Refer to Operation and Maintenance Manual, “Oil Filter - Inspect”. 4. Clean the filter mounting base with a clean cloth. Make sure that the old filter gasket has been removed. 5. Apply a thin film of clean engine oil to the sealing surface of the new filter element. 6. Install the new filter element by hand.
129 Maintenance Section Engine Valve Lash and Fuel Injector Timing - Check i00058667 i00079668 Engine Valve Lash and Fuel Injector Timing - Check Air Conditioner - Test (If Equipped) SMCS Code: 1102 SMCS Code: 7320 Refer to the Service Manual for the complete adjustment procedure for the engine valve lash. NOTICE Refrigerant in the air conditioner system can cause personal injury. Avoid any contact with refrigerant.
130 Maintenance Section Air Conditioner Belt - Inspect/Adjust/Replace i00079675 Air Conditioner Belt Inspect/Adjust/Replace SMCS Code: 1357; 7320 1. Stop the engine in order to inspect the air conditioner belt. Illustration 219 g00107592 4. Loosen the adjusting locknut (1). Loosen the compressor bracket mounting bolt (2). 5. Move the compressor until the correct belt tension is reached. Illustration 217 g00105056 2. Remove the engine access panel on the left side of the machine.
131 Maintenance Section Alternator and Fan Belts - Inspect/Adjust/Replace i00079712 Alternator and Fan Belts Inspect/Adjust/Replace SMCS Code: 1357 If new belts are installed, check belt adjustment after 30 minutes of operation. For multiple belt drive applications, always replace the belts in matched sets. Replacing only one belt of a matched set will cause the new belt to carry more load because the older belts are stretched. The additional load on the new belt could cause the new belt to break.
132 Maintenance Section Cooling System Coolant Additive (DEAC) - Add i00081332 Cooling System Coolant Additive (DEAC) - Add SMCS Code: 1352; 1353; 1395 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. Note: This procedure pertains to Caterpillar Diesel Engine Antifreeze/Coolant (DEAC) only.
133 Maintenance Section Differential Oil Level (Front) - Check i00081450 i00081469 Differential Oil Level (Front) Check Differential Oil Level (Rear) Check SMCS Code: 3258 SMCS Code: 3258 The oil level/fill plug is located near the middle of the front axle. The oil level/fill plug is located near the middle of the rear axle. Illustration 225 g00105014 1. Remove the oil level/fill plug in order to check the oil. 2. The oil level should be at the bottom of the plug threads.
134 Maintenance Section Extendable Stick - Inspect i00081579 i00081581 Extendable Stick - Inspect (If Equipped) Final Drive Oil Level (Front) Check SMCS Code: 6533 SMCS Code: 4050 Check the extendable stick for slop. Shim the extendable stick pads in order to maintain an acceptable fit and reduce slop. Consult the Service Manual for the correct procedure. Note: Do not over apply a silicone based lubricant.
135 Maintenance Section Water Pump Belt - Inspect/Adjust/Replace i00111650 Water Pump Belt Inspect/Adjust/Replace i00081491 Drive Shaft Spline - Lubricate SMCS Code: 3253 SMCS Code: 1357; 1361 Illustration 230 Illustration 228 g00107717 Illustration 229 g00107716 1. To adjust the water pump belt, loosen the mounting bolt (1) for the idler pulley and the bracket bolt (2) for the idler pulley. 2. Move the idler pulley in order to obtain the correct adjustment. The belt should deflect 13 to 19 mm (0.
136 Maintenance Section Drive Shaft Universal Joint - Lubricate i00081486 i00081585 Drive Shaft Universal Joint Lubricate Fuel System Primary Filter Replace SMCS Code: 3251; 3253 SMCS Code: 1260; 1261 Illustration 232 g00107920 Illustration 235 g00107638 Illustration 236 g00107637 Apply lubricant to the grease fittings for the universal joints of the rear drive shaft. There are two grease fittings. 1. Loosen collar (1). Illustration 233 g00107941 2.
137 Maintenance Section Fuel System Secondary Filter - Replace i00117896 Fuel System Secondary Filter Replace SMCS Code: 1261 Illustration 237 g00105056 1. Remove the engine access panel on the left side of the machine. Illustration 238 g00107648 2. Remove the fuel filter. Inspect the fuel filter for debris by cutting the filter open. Discard the filter properly. 3. Clean the mounting base of the fuel filter. Remove any part of the old seal that remains on the mounting base of the fuel filter. 4.
138 Maintenance Section Hydraulic System Oil Filter - Replace i00091375 Hydraulic System Oil Filter Replace SMCS Code: 5056; 5068 Illustration 242 g00106815 3. Remove the filter element with a strap type wrench. Illustration 239 g00105008 4. Clean the filter element mounting base. Remove any part of the filter element gasket that remains on the filter element mounting base. 5. Apply a light coat of oil to the gasket of the new filter element. 6. Install the new filter element by hand.
139 Maintenance Section Transmission Oil Filter - Replace i00095358 Transmission Oil Filter Replace 6. Move the transmission control lever to NEUTRAL and engage the parking. Inspect the filter element for leaks. SMCS Code: 3067 Illustration 246 Illustration 244 g00107040 The transmission filter is located on the right side of the machine . Illustration 245 g00107041 1. Remove the transmission oil filter element with a strap type wrench. 2. Clean the filter element mounting base.
140 Maintenance Section Differential Oil (Front) - Change i00081397 i00119351 Differential Oil (Front) - Change Differential Oil (Rear) - Change SMCS Code: 3258 SMCS Code: 3258 Illustration 247 g00105013 Illustration 249 g00105015 1. Remove the oil drain plug and drain the oil into a suitable container. 1. Remove the oil drain plug and drain the oil into a suitable container. 2. Clean the drain plug and install the drain plug. 2. Clean the drain plug and install the drain plug.
141 Maintenance Section Engine Crankcase Breather - Clean i00081526 Engine Crankcase Breather Clean SMCS Code: 1317 6. Inspect the breather hose for damage. Replace the breather hose, if necessary. 7. Install the breather element. Install the breather element cover assembly. 8. Install the breather hose and breather outlet hose clamp. 9. Replace the engine access panel. Illustration 251 g00105056 Remove the engine access panel on the left side of the machine.
142 Maintenance Section Final Drive Oil (Front) - Change i00081580 Final Drive Oil (Front) - Change SMCS Code: 4050 i00119141 Rollover Protective Structure (ROPS) - Inspect SMCS Code: 7325 1. Remove the access covers from both sides of the ROPS. 2. Inspect the ROPS for loose bolts or for damaged bolts. Replace any damaged bolts or missing bolts with original equipment parts only. Tighten the M16 bolts to a torque of 240 ± 40 N·m (175 ± 30 lb ft).
143 Maintenance Section Transmission Magnetic Screen - Clean i00094956 Transmission Magnetic Screen - Clean SMCS Code: 3030 1. Drain the transmission oil. See Operation and Maintenance Manual, “Transmission Oil Change”. Illustration 255 i00095354 Transmission Oil - Change SMCS Code: 3030; 3080 Operate the machine for a few minutes in order to warm the transmission oil. The machine should be level. Lower the bucket to the ground and apply slight downward pressure.
144 Maintenance Section Wheel Bearings (Front) - Lubricate i00095429 Wheel Bearings (Front) Lubricate SMCS Code: 4205; 4208 Use the following procedure for both wheels. 1. Raise the front wheels slightly off the ground. 2. Install sufficient blocking under the frame and lower the machine to the blocking. Illustration 258 g00107039 3. Remove the nuts and both wheels. 5. Remove the dipstick/fill cap and fill the transmission with transmission oil.
145 Maintenance Section Engine Governor Screen - Inspect/Clean/Replace 12. Install the hub, the bearings, the washer, the nut and the wheel. 13. While you turn the wheel, tighten the nut (3) until a slight drag is noticed. Back off the nut to the nearest slot and install the cotter pin. i00081531 Engine Governor Screen Inspect/Clean/Replace SMCS Code: 1264 14. All bearing surfaces must make contact. The wheel should turn freely within 0.025 to 0.25 mm (0.001 to 0.010 inch) end play. 15.
146 Maintenance Section Hydraulic System Oil - Change i00091363 Hydraulic System Oil - Change SMCS Code: 5056 Operate the machine for a few minutes in order to warm the hydraulic system oil. The machine should be level . Lower the bucket to the ground and apply slight downward pressure. Engage the parking brake and stop the engine.
147 Maintenance Section Cooling System Coolant (DEAC) - Change i00081314 Cooling System Coolant (DEAC) - Change SMCS Code: 1352; 1353; 1395 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. Illustration 266 g00106776 6. Maintain the hydraulic oil level in the sight gauge between the “ADD” mark and the “FULL” mark.
148 Maintenance Section Cooling System Coolant Extender (ELC) - Add • Operation and Maintenance Manual, “Cooling System Specifications” • Operation and Maintenance Manual, “Refill Capacities” 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. 9. Start the engine. Run the engine without the radiator cap until the thermostat opens and the coolant level stabilizes. Illustration 268 g00105009 2.
149 Maintenance Section Cooling System Water Temperature Regulator - Clean/Replace For additional information on the addition of extender, see Operation and Maintenance Manual, “Caterpillar Coolant Recommendations” or consult your Caterpillar dealer. i00081359 Cooling System Water Temperature Regulator Clean/Replace SMCS Code: 1355; 1393 Replace the thermostat on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system.
150 Maintenance Section Cooling System Coolant (ELC) - Change • The thermostat is tested and the thermostat meets test specifications. i00095660 • The thermostat is not damaged. Cooling System Coolant (ELC) - Change • The thermostat does not have excessive SMCS Code: 1353; 1395 buildup of deposits. 5. Install the hose. Tighten the hose clamp. 6. Refill the cooling system. See Operation and Maintenance Manual, “Cooling System Specifications” and Operation and Maintenance Manual, “Refill Capacities”.
