1. Coulter Act Diff Service Manual

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. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt ® ® © 2010 Caterpillar All Rights Reserved.

SEBU7879-15 April 2012 Operation and Maintenance Manual 980H Wheel Loader A8J1-Up (980H) JMS1-Up (980H) KZL1-Up (980H) MHG1-Up (980H) SAFETY.CAT.COM. SEBU7879-15 Maintenance Section Maintenance Interval Schedule Bucket Hinge and Lift Arm Clearance Shims - i04876432 Inspect/Adjust/Replace.127 Maintenance Interval Schedule Bucket Tips - Inspect/Replace.129 Bucket Wear Plates - Inspect/Replace.132 SMCS Code: 7000 Camera - Clean.132 Circuit Breakers - Reset. SEBU7879-15 Maintenance Section Maintenance Interval Schedule Every 250 Service Hours or Monthly Hydraulic Tank Breaker Relief Valve - Clean.166 Service Brake Wear Indicator - Check.175 Battery - Clean.

123 Steering Column Spline (Command Control Steering) Belt - Inspect/Adjust/Replace. Reference: Before any service work is performed on the lubrication system, refer to Special Instructions, After the reservoir has been filled with the REHS1396 or consult your Caterpillar dealer. Recommended lubricant, loosen the fitting to the supply line. Operate the pump until lubricant flows. SEBU7879-15 Maintenance Section Axle Oscillation Bearings - Lubricate The Automatic TWIN Greasing If pumping becomes difficult, the filter behind the coupling of the pump may be clogged.

Also check the System coupling of the filler pipe. Remove the clogged parts and clean the clogged parts. SEBU7879-15 Maintenance Section Battery - Clean Clean the battery terminals and the surfaces of the batteries with a clean cloth.

Coat the battery terminals with petroleum jelly. Make sure that the battery cables are installed securely. Repeat for the battery compartment on the left rear side of the machine. SEBU7879-15 Maintenance Section Battery or Battery Cable - Inspect/Replace Recycle the Battery i03657099 Battery or Battery Cable - Always recycle a battery. Never discard a battery. Inspect/Replace Always return used batteries to one of the following locations: SMCS Code: 1401-040; 1401-510; 1402-040; 1402-510.

Engage the parking brake. Lower the Testing and Adjusting Service Manual of the braking implement to the ground. Stop the engine. System for your machine or consult your Caterpillar dealer. If the machine moved during the test, consult your Caterpillar dealer for a brake inspection.

If the opposite side of the cutting edge is not worn, If the machine moved during the test, consult your use the opposite side of the cutting edge. The end Caterpillar dealer for a brake inspection. Make any bits are not reversible.

Necessary repairs before the machine is returned to operation. Inspect the Linkage g00879740 Illustration 144 Inspect the wear plates. Replace the wear plates before damage to the bottom of the bucket occurs.

Consult your Caterpillar dealer for replacement of wear plates. G03003577 Illustration 145 (1) Lift Arm (2) Bucket (3) Inspection Points for the Bucket Hinge. SEBU7879-15 Maintenance Section Bucket Linkage and Loader Cylinder Bearings - Lubricate i02231274 Bucket Linkage and Loader Cylinder Bearings - Lubricate SMCS Code: 5102-086-BD; 5104-086-BD; 6107-086-BD g01345720 Illustration 146 (2) Bucket (4) Install washers on lift arm.

Install washers and pin assembly to the bucket. When possible, use washers on both sides of the lift arm to reduce the gap between the lift arm and the hinges on the bucket. SEBU7879-15 Maintenance Section Bucket Lower Pivot Bearings - Lubricate Note: If necessary, the work tool may need to be tilted forward in order to apply lubricant to the lower pivot bearing. I03657242 Bucket Tips - Inspect/Replace SMCS Code: 6805-040; 6805-510 Personal injury or death can result from the bucket falling.

SEBU7879-15 Maintenance Section Bucket Tips - Inspect/Replace g00590670 g00101359 Illustration 151 Illustration 153 (4) Back of Pin-Master 4. Install the new bucket tip onto the adapter.

(5) Extractor a. Place the Pin-Master on the bucket tooth.

Note: The bucket tip can be rotated by 180 degrees in order to allow greater penetration or less penetration. Illustration 155 i01922739 Note: Retainers are often damaged during the Bucket Upper Pivot Bearings removal process. Caterpillar recommends the installation of a new retainer when bucket tips are - Lubricate rotated or replaced. SMCS Code: 6001-086-BD; 6107-086-BD Wipe all fittings before you apply lubricant. Inspect the wear plates. Replace the wear plates nonsudsing household detergent.

Before damage to the bottom of the bucket occurs. Consult your Caterpillar dealer for replacement of 4.

If water and detergent are used to clean the filter wear plates. SEBU7879-15 Maintenance Section Case Drain Screen (Strainer) (Steering Pump, Hydraulic Fan Pump, Motor) - Clean Display i02050852 Case Drain Screen (Strainer) (Steering Pump, Hydraulic Fan Pump, Motor) - Clean SMCS Code: 4304-070-Z3; 5057-070-Z3 The screen is located in the case drain line near the hydraulic oil tank. Refer to Special Publication, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar Tilt Hood Actuator (3) – 60 amp products. Dispose of all fluids according to local regulations and mandates. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specification for pre-mixed or concentrate coolants. Use only Extender with Cat ELC.

Failure to follow these recommendations can result in shortened cooling system component life. Refer to Special Publication, NENG2500, “Caterpillar the engine hood at the rear of the machine. Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar 1. Open the engine hood. Slowly loosen cooling system pressure cap (1) in Dispose of all fluids according to local regulations and. SEBU7879-15 Maintenance Section Cooling System Coolant Level - Check Reference: Refer to Operation and Maintenance 4.

If the coolant level is low, slowly remove cooling Manual, “Capacities (Refill)” for the correct system pressure cap in order to relieve system amount. For additional information about coolant analysis, see Submit the sample for Level 2 analysis. Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations” or consult your Caterpillar For additional information about coolant analysis, see dealer. Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations”. And replace if worn or damaged. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates. SEBU7879-15 Maintenance Section Differential and Final Drive Oil - Change g00864014 Illustration 176 Rear view 2. Remove front differential drain plug (3) and allow the oil to drain into a suitable container. Clean the drain plug and install the drain plug. G01387238 Illustration 177 3. fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar g00864019 products. Illustration 180 Front view Dispose of all fluids according to local regulations and. SEBU7879-15 Maintenance Section Differential and Final Drive Oil Sample - Obtain Differentials Final Drives g00535224 g00760182 Illustration 181 Illustration 183 Front Differential Filler Plug 1. Position the wheel so that the final drive filler plug is level with the centerline of the wheel. Remove the final drive filler plug. Reposition the machine in a Reference: Refer to Special Publication, SEBU6250, straight direction without articulation. “Caterpillar Machine Fluids Recommendations” for more information about obtaining an fluid sample.

Lower the bucket to the ground. Apply a slight down pressure. The timing pins must be removed from the camshafts before the crankshaft is turned or damage to the cylinder block will be the result. The operation of Caterpillar engines with improper adjustments of the electronic unit injector can reduce engine efficiency. This reduced efficiency could result in excessive fuel usage and/or shortened engine component life.

Cleaning Primary Air Filter Elements NOTICE Caterpillar recommends certified air filter cleaning ser- vices that are available at Caterpillar dealers. The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt to clean the filter element. SEBU7879-15 Maintenance Section Engine Air Filter Secondary Element - Replace Vacuum Cleaning Vacuum cleaning is another method for cleaning primary air filter elements which require daily cleaning because of a dry, dusty environment. Cleaning with pressurized air is recommended prior to vacuum cleaning.

SEBU7879-15 Maintenance Section Engine Air Filter Secondary Element - Replace g00882913 Illustration 196 4. Remove the secondary filter element.

G01959139 Illustration 194 1. Access the air cleaner from the right side of the machine.

Open the access door. G00882914 Illustration 197 5. SEBU7879-15 Maintenance Section Engine Air Filter Service Indicator - Inspect i01968230 i01968211 Engine Air Filter Service Engine Air Filter Service Indicator - Inspect Indicator - Inspect/Replace SMCS Code: 7452-040 SMCS Code: 7452-040; 7452-510 Some engines are equipped with a differential gauge Some engines are equipped with a differential gauge for inlet air pressure. Clean Refer to Special Publication, NENG2500, “Caterpillar SMCS Code: 1317-070 Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates. If you select an interval for oil and filter change that is Dealer Service Tool Catalog” for tools and supplies too long, you may damage the engine. Suitable to collect and contain fluids on Caterpillar products. The normal engine oil change interval is listed in this Operation and Maintenance Manual, “Maintenance.

Weather Recommendations for All Caterpillar Machines”. Poor maintenance of air filters or of fuel Machines” filters requires reduced oil change intervals.

Consult your Caterpillar dealer for more information if this Reference: Special Publication, PEDP7035, product will experience abnormally harsh operating “Optimizing Oil Change Intervals”. Illustration 204 Instructions for the installation of the filters are Newer machine models printed on the side of each Caterpillar spin-on filter. For non-Caterpillar filters, refer to the Location of crankcase drain valve installation instructions that are provided by the 2.

If a valve rotator fails to rotate, consult your SMCS Code: 1109-040 Caterpillar dealer for service. Note: Caterpillar recommends replacing valve rotators that are operating improperly. An improperly When inspecting the valve rotators, protective operating valve rotator will shorten valve life because glasses or face shield and protective clothing of accelerated wear on the valves. Refer to Special Publication, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates. Refer to Special Publication, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products.

G01109758 Illustration 212 Dispose of all fluids according to local regulations and mandates. For non-Caterpillar filters, use the instructions that are provided with the filter. Note: You may need to use a Caterpillar strap wrench, or another suitable tool, in order to turn the filter to the amount that is required for final installation.

Remove the fuel tank breaker relief valve from the top of the fuel tank. Note: You may need to use a Caterpillar strap wrench, or another suitable tool, in order to turn 2. Install a new fuel tank breaker relief valve. Refer to Special Publication, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. If it is necessary to replace fuses frequently, an electri- (1) HVAC Blower.20 Amperes cal problem may exist. Contact your Caterpillar dealer.

(2) Neutralizer Override Switch. 10 Amperes Fuses – The fuses protect the electrical. SEBU7879-15 Maintenance Section High Intensity Discharge Lamp (HID) - Replace (11) Turn Signal Flasher, Front Flood Relays, and i02245859 Rear Flood Relays.10 Amperes High Intensity Discharge Lamp (HID) - Replace (12) Machine Security System and Product Link.10 Amperes (If Equipped) (13) LH Indicator Display and RH Indicator SMCS Code: 1434-510. Dispose of all fluids according to local regulations and mandates. Instructions for the installation of the filters are printed on the side of each Caterpillar spin-on filter. For non-Caterpillar filters, refer to the 1. Stop the engine.

Installation instructions that are provided by the supplier of the filter. Heavy-duty diesel engine oils with a minimum zinc content of 900 ppm Selection of the Oil Change Interval If Caterpillar oils cannot be used, use heavy-duty oils with the following classification: Caterpillar ECF-1, Your machine may be able to use a 4000 hour API CG-4, API CF, and TO-4. Refer to Special Publication, NENG2500, “Caterpillar nents can occur. Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar 5. Remove the pipe nipple in order to close the drain products.

Install the drain plug. SEBU7879-15 Maintenance Section Hydraulic System Oil Filter - Replace Note: If the pump is difficult to prime, in order to aid Note: The oil must be free of air bubbles. If air pump priming, refer to Illustration 225 and 226. Install bubbles are present in the hydraulic oil, air is entering the 5P-3415 Adapter (1) after removing the fitting the hydraulic system.

Refer to Operation and Maintenance Manual, “Lubricant Viscosities”. Instructions for the installation of the filters are printed on the side of each Caterpillar spin-on 4. Clean the filler cap and install the filler cap. For non-Caterpillar filters, refer to the installation instructions that are provided by the 5.

SEBU7879-15 Maintenance Section Hydraulic System Oil Level - Check i02214455 i01920994 Hydraulic System Oil Level - Hydraulic System Oil Sample Check - Obtain SMCS Code: 5056-535-FLV SMCS Code: 5050-008; 5056-008; 7542 g00274518 Illustration 231 Obtain a sample of the hydraulic oil from the sampling valve. Small amounts of debris may be found in the filter element. This could be caused by friction and by normal wear. Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found. SEBU7879-15 Maintenance Section Pallet Fork - Inspect i04004068 Pallet Fork - Inspect SMCS Code: 6136-040 Descriptions of the Fork Tine Parts g01598401 Illustration 235 (1) Blade – The horizontal part of the fork tine that supports the load (2) Heel – The radius on the fork tine that connects the blade to the shank (3) Shank –. SEBU7879-15 Maintenance Section Pallet Fork - Inspect (8) Front Face of Shank – The distance for the load center is measured from the front face of the shank and the face of the shank contacts the load. (9) Flanks – The side faces of the blade and the shank.

SEBU7879-15 Maintenance Section Pallet Fork - Inspect 1. Measure the thickness of the shank. Ensure that the measuring device is held square across the shank in order to acquire an accurate measurement. G01600076 Illustration 241 2.

Coulter Act Diff Service Manual

Move the upper arm of the measuring device toward the face of the shank. Open the side access panels on each side of the radiator. G01563115 Illustration 243 typical example 2. Coat the mounting holes for the quick coupler with grease. Reference: Refer to Operation and Maintenance Manual, SEBU6250, “Caterpillar Machine Lubricant g00101939 Illustration 245 Recommendations” for information on lubricants. SEBU7879-15 Maintenance Section Receiver Dryer (Refrigerant) - Replace 4. You can use compressed air, high-pressure water, or steam to remove dust and other debris from the radiator fins.

The maximum air pressure for cleaning purposes must be reduced to 205 kPa (30 psi). The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi). SEBU7879-15 Maintenance Section Ride Control Accumulator - Check i01568401 Automatic Ride Control – Press the top Ride Control Accumulator - of the ride control switch in order to activate Check the automatic ride control system. The ride control system will automatically turn on if the ground speed exceeds 9.6 km/h (6 mph). Seat Belt - Inspect Do not repair the ROPS by welding reinforcement i04421974 plates to the ROPS. Consult your Caterpillar dealer Seat Belt - Replace for repair of cracks in any welds, in any castings, or in any metal section of the ROPS.

The service brake must be checked in order to en- Adjusting, “Braking System” for the machine that is sure proper operation before you test the supple- being serviced or consult your Caterpillar dealer. Mental steering system.

I03589859 Personal injury, death, or property damage could. SMCS Code: 4303-086-BD Do not operate the machine until the inspection and repair are completed. Contact your Caterpillar dealer for any other required service. I02585698 Steering Column Spline (Command Control Steering) - Lubricate SMCS Code: 4310-086-SN. SEBU7879-15 Maintenance Section Steering Pilot Oil Screen (Command Control Steering) - Clean/Replace i01458229 i02305841 Steering Pilot Oil Screen Tire Inflation - Check (Command Control Steering) - SMCS Code: 4203-535-AI Clean/Replace SMCS Code: 4304-070-Z3; 4304-510-Z3 g01160201 Illustration 256 Always obtain proper tire inflation pressures and maintenance recommendations for the tires on your machine from your tire supplier. SEBU7879-15 Maintenance Section Transmission Oil - Change 10.

Install three magnets on magnetic screen tube assembly (3). Insert suction screen(4) and magnetic screen tube assembly (3) in the housing. Install the cover and four bolts. Remove transmission oil filler cap (1) on the left side of the machine. SEBU7879-15 Maintenance Section Transmission Oil Filter - Replace 6.

Inspect the filter housing seal. Replace the seal i04004116 if the seal is damaged. Transmission Oil Filter - Replace 7. Insert a new transmission oil filter element into the transmission filter housing.

SMCS Code: 3004-510. Window Washer Reservoir - Fill SMCS Code: 7306-544 NOTICE When operating in freezing temperatures, use Caterpillar nonfreezing window washer solvent or g00763272 Illustration 263 equivalent.

System damage can result from freezing. SEBU7879-15 Maintenance Section Windows - Clean Polycarbonate Windows (If Inspect the condition of the wiper blades.

Replace the wiper blades if the wiper blades are worn or equipped) damaged. If the wiper blades streak the window, replace the wiper blades. Wash polycarbonate windows with a mild soap or detergent.

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