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2010 Caterpillar
All Rights Reserved
SEBU7821-04
June 2007
Operation and
Maintenance
Manual
416D, 420D, 424D, 428D, 430D, 432D
and 442D Backhoe Loaders
RXA1-Up (Machine)
BKC920-Up (Machine)
BMC1060-Up (Machine)
BXC1-Up (Machine)
B2D1-Up (Machine)
TBD1-Up (Machine)
BGJ1050-Up (Machine)
SMJ1-Up (Machine)
BNK5900-Up (Machine)
BML4800-Up (Machine)
MBM1-Up (Machine)
BLN10300-Up (Machine)
BFP12900-Up (Machine)
FDP18400-Up (Machine)
WEP1-Up (Machine)
TDR1-Up (Machine)
DSX1-Up (Machine)
CJZ1-Up (Machine)
128
Maintenance Section
Maintenance Interval Schedule
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165
166
166
169
170
When Required
Battery or Battery Cable - Inspect/Replace ........
Bucket Cutting Edges - Inspect/Replace ............
Bucket Tips - Inspect/Replace ............................
Cab Interior - Clean ............................................
Engine Air Filter Primary Element - Clean/
Replace .............................................................
Engine Air Filter Secondary Element - Replace ..
Engine Compartment - Clean .............................
Fuel System - Prime ...........................................
Fuses - Replace ..................................................
Oil Filter - Inspect ................................................
Radiator Core - Clean .........................................
Window Washer Reservoir - Fill ..........................
Window Wipers - Inspect/Replace ......................
Windows - Clean .................................................
132
134
135
137
145
147
148
153
156
162
163
170
171
171
130
130
132
143
144
149
150
152
152
160
165
140
144
144
145
149
153
153
154
157
159
168
169
142
142
151
152
164
166
167
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Every Year
Cooling System Coolant Sample (Level 2) Obtain ............................................................... 141
Refrigerant Dryer - Replace ................................ 164
129
Maintenance Section
Maintenance Interval Schedule
130
Maintenance Section
Axle Breathers - Clean/Replace
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Illustration 224
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The front axle breather is located on the top right side of the
differential housing.
Illustration 225
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Illustration 226
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Maintenance Section
Backhoe Boom, Stick, Bucket, and Cylinder Bearings - Lubricate
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Illustration 229
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Illustration 228
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132
Maintenance Section
Battery or Battery Cable - Inspect/Replace
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Illustration 230
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Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510
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.
1. Empty the bucket. Remove the pin that secures
the brace for the loader lift arm to the left loader lift
arm. Raise the loader arm to the maximum height.
2. Position the brace for the loader lift arm over the
left lift cylinder rod with the flat end against the
cylinder end.
3. Push the pin through the holes of the brace for the
loader lift arm and install the cotter pin.
4. Slowly lower the loader arms until the brace for the
loader lift arm contacts the top of the lift cylinder
and the bosses on the loader arm.
Illustration 231
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Maintenance Section
Brake Reservoir Oil Level - Check
Illustration 232
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Illustration 234
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134
Maintenance Section
Bucket Cutting Edges - Inspect/Replace
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Maintenance Section
Bucket Tips - Inspect/Replace
Check the bucket tips for wear. If the bucket tip has a
hole, replace the bucket tip.
1. Remove the pin from the bucket tip. The pin can
be removed by one of the following methods.
g00590670
Bucket Tips
Illustration 237
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(6) Retainer
(7) Retaining washer
(8) Adapter
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136
Maintenance Section
Cab Air Filter - Clean/Replace
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Illustration 238
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Illustration 239
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Maintenance Section
Cab Interior - Clean
Illustration 241
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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 242
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NOTICE
Mixing ELC with other products will reduce the effectiveness of the coolant.
This could result in damage to cooling system components.
If Caterpillar products are not available and commercial products must be used, make sure they
have passed the Caterpillar EC-1 specification for
pre-mixed or concentrate coolants and Caterpillar
Extender.
138
Maintenance Section
Cooling System Coolant (ELC) - Change
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4. Slowly lower the loader arms until the brace for the
loader lift arm contacts the top of the lift cylinder
and the bosses on the loader arm.
Illustration 243
g01029869
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.
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 brace for the loader lift arm to the left loader lift
arm. Raise the loader arm to the maximum height.
2. Position the brace for the loader lift arm over the
left lift cylinder rod with the flat end against the
cylinder end.
3. Push the pin through the holes of the brace for the
loader lift arm and install the cotter pin.
Illustration 244
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Maintenance Section
Cooling System Coolant Extender (ELC) - Add
g00293559
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Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loose the cap slowly to relieve
the pressure.
When a Caterpillar Extended Life Coolant is
used, an extender must be added to the cooling
system. See the Operation and Maintenance
Manual, Maintenance Interval Schedule for the
proper service interval. The amount of extender is
determined by the cooling system capacity.
Table 82
Recommended Amount
of Extender
22 to 30 L (6 to 8 US gal)
30 to 38 L (8 to 10 US gal)
38 to 49 L (10 to 13 US gal)
49 to 64 L (13 to 17 US gal)
140
Maintenance Section
Cooling System Coolant Level - Check
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NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
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 247
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Illustration 248
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Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
Illustration 249
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142
Maintenance Section
Differential Oil (Front) - Change
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Illustration 250
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Illustration 251
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1. Remove oil drain plug (1) and drain the oil into a
suitable container.
2. The drain plug is magnetic. Check the plug for
metal.
3. Clean the drain plug and install the drain plug.
4. Remove oil level/fill plug (2).
5. Add oil until the oil is level with the threads for the
filler plug. Refer to Operation and Maintenance
Manual, Lubricant Viscosities and Operation and
Maintenance Manual, Capacities (Refill) for oil.
6. Clean the filler plug and install the filler plug.
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Maintenance Section
Differential Oil Level (Front) - Check
Rear Axle
Illustration 252
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1. Remove the oil drain plug and drain the oil into a
suitable container.
2. Clean the drain plug and install the drain plug.
Illustration 254
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1. Remove the oil drain plug and drain the oil into a
suitable container.
2. Clean the drain plug and install the drain plug.
Illustration 253
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Illustration 255
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144
Maintenance Section
Differential Oil Level (Rear) - Check
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Illustration 256
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Illustration 258
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Illustration 257
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Illustration 259
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Maintenance Section
Drive Shaft Spline - Lubricate
Illustration 262
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NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.
Service the air cleaner filter element when the
yellow piston on the engine air filter service
indicator enters the red zone or the indicator
reads 63.5 cm (25 inch) of water. Refer to
Operation and Maintenance Manual, Engine Air
Filter Service Indicator - Inspect.
1. Open the engine access door on the top of the
machine.
Illustration 261
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Illustration 263
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146
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
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NOTICE
Do not clean the air filter elements by bumping or tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets, or seals. Damaged elements will allow dirt to pass through. Engine
damage could result.
Visually inspect the primary air filter elements before
cleaning. Inspect the air filter elements for damage
to the seal, the gaskets, and the outer cover. Discard
any damaged air filter elements.
There are two common methods that are used to
clean primary air filter elements:
Pressurized air
Vacuum cleaning
Pressurized Air
Pressurized air can be used to clean primary air filter
elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi).
Note: When the primary air filter elements are
cleaned, always begin with the clean side (inside)
in order to force dirt particles toward the dirty side
(outside).
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. Vacuum cleaning will not remove deposits
of carbon and oil.
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Maintenance Section
Engine Air Filter Secondary Element - Replace
Date of cleaning
Number of cleanings
i01991054
NOTICE
Always replace the secondary filter element. Never
attempt to reuse it by cleaning.
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.
Illustration 265
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148
Maintenance Section
Engine Compartment - Clean
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Personal injury can result from parts and/or covers under spring pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.
4. Remove the screws (2). Remove the plate (3).
5. Remove the diaphragm (4) and the cap (6).
Remove the spring (7). Discard diaphragm (4).
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Illustration 266
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NOTICE
Do not overfill the crankcase. Engine damage can result.
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Maintenance Section
Engine Oil Sample - Obtain
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Illustration 267
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Illustration 269
Illustration 268
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Illustration 270
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150
Maintenance Section
Engine Valve Lash - Check
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Illustration 271
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Illustration 272
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Maintenance Section
Final Drive Oil (Front) - Change
Illustration 273
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Illustration 274
Illustration 275
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Illustration 276
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152
Maintenance Section
Final Drive Oil (Rear) - Change
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Illustration 279
Illustration 277
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Illustration 278
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3. Add oil until the oil is level with the plug threads.
Refer to Operation and Maintenance Manual,
Lubricant Specifications and Operation and
Maintenance Manual, Capacities (Refill) for the
oil.
4. Clean the plug and install the plug.
5. Repeat the procedure for the other final drive.
Illustration 280
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Maintenance Section
Final Drive Oil Sample (Front) - Obtain
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154
Maintenance Section
Fuel System Filter and Water Separator - Replace
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Illustration 283
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NOTICE
It is extremely important to drain water from the water
separator daily, or every ten hours. It is also extremely
important to drain water from the fuel tank weekly, or
every 50 hours. Failure to do so could result in damage
to the fuel system.
1. Empty the bucket. Remove the pin that secures
the brace for the loader lift arm to the left loader lift
arm. Raise the loader arm to the maximum height.
2. Position the brace for the loader lift arm over the
left lift cylinder rod with the flat end against the
cylinder end.
3. Push the pin through the holes of the brace for the
loader lift arm and install the cotter pin.
4. Slowly lower the loader arms until the brace for the
loader lift arm contacts the top of the lift cylinder
and the bosses on the loader arm.
5. Stop the engine.
Illustration 284
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Maintenance Section
Fuel System Water Separator - Drain
i01986280
Illustration 285
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NOTICE
It is extremely important to drain water from the water
separator daily, or every ten hours. It is also extremely
important to drain water from the fuel tank weekly, or
every 50 hours. Failure to do so could result in damage
to the fuel system.
Illustration 287
Illustration 286
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Illustration 288
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156
Maintenance Section
Fuel Tank Water and Sediment - Drain
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Fuses - Replace
SMCS Code: 1417
Fuses protect the electrical system from damage
that is caused by overloaded circuits. Replace the
fuse if the element separates. If the element of a new
fuse separates, check the circuit. Repair the circuit, if
necessary.
NOTICE
Replace the 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 Caterpillar dealer
Illustration 290
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Illustration 289
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Maintenance Section
Hydraulic Oil Sample - Obtain
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Illustration 293
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Illustration 292
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158
Maintenance Section
Hydraulic System Oil - Change
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Illustration 295
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Illustration 296
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Illustration 294
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Maintenance Section
Hydraulic System Oil Filter - Replace
Illustration 297
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Illustration 299
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Illustration 300
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Illustration 298
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160
Maintenance Section
Hydraulic System Oil Level - Check
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Illustration 301
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Illustration 302
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Illustration 304
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Maintenance Section
Loader Bucket, Cylinder, and Linkage Bearings - Lubricate
Apply lubricant to the grease fitting (7) for the rod end
of the tilt cylinder.
Illustration 305
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162
Maintenance Section
Oil Filter - Inspect
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Check Procedure
Check the area around the machine. Make sure
that the machine is clear of personnel and clear of
obstacles.
Check the brakes on a dry, level surface.
Fasten the seat belt before you check the brakes.
Illustration 306
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Illustration 307
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Maintenance Section
Radiator Core - Clean
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Illustration 310
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Adjustment Procedure
If the machine moved during the test, perform the
following procedure in order to adjust the parking
brake.
1. Apply the service brakes.
NOTICE
Do not spray high pressure water into the radiator
while the engine is running.
Note:
Illustration 308
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164
Maintenance Section
Refrigerant Dryer - Replace
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Illustration 312
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Typical example
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Maintenance Section
Seat Belt - Replace
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Illustration 313
(1) Date
(2) Date
(3) Date
(4) Date
g01152685
of installation (retractor)
of installation (buckle)
of manufacture (tag) (fully extended web)
of manufacture (underside) (buckle)
Illustration 315
Illustration 314
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166
Maintenance Section
Swing Frame and Cylinder Bearings - Lubricate
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Illustration 316
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Illustration 317
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Illustration 318
Magnetic strainer cover for the power shift transmission
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Maintenance Section
Transmission Oil - Change
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Illustration 321
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168
Maintenance Section
Transmission Oil Filter - Replace
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Illustration 322
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Illustration 323
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Illustration 324
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Maintenance Section
Transmission Oil Level - Check
Illustration 325
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Illustration 327
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170
Maintenance Section
Wheel Nut Torque - Check
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Illustration 328
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6. Pull the hub assembly (4) until the cone and roller
assembly come out of the hub assembly. Then,
pull off the hub all the way.
7. Clean all of the parts in clean, nonflammable
solvent and allow the parts to air dry. Do not use
pressure air.
8. Inspect the roller assemblies for heat discoloration
and for wear. Inspect the seals for damage.
Replace any damaged parts.
9. Make sure that the grease gets packed between
the rollers and the cage on both bearings.
Force the grease through the bearing from the
large end of the rollers.
10. Pack a 6 mm (0.25 inch) layer of grease between
the bearing assemblies in the hub. Do not pack
the hub fully with grease.
11. Apply a 6 mm (0.25 inch) thick film of grease on
the spindle surface.
12. Install the hub, the bearings, the washer, the nut
and the wheel.
13. While you turn the wheel, tighten bolt (2) until a
slight drag is noticed.
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. Install the dust cap.
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Maintenance Section
Window Wipers - Inspect/Replace
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Windows - Clean
SMCS Code: 7310; 7340
S/N: RXA1-Up
S/N: BKC920-Up
S/N: BMC1060-Up
S/N: BXC1-Up
S/N: B2D1-Up
Illustration 330
g01031223
S/N: TBD1-Up
S/N: BGJ1050-Up
S/N: SMJ1-Up
S/N: BNK5900-Up
S/N: BML4800-Up
S/N: MBM1-Up
S/N: BLN10300-Up
S/N: FDP18400-Up
S/N: WEP1-Up
S/N: TDR1-Up
i01437556
S/N: DSX1-Up
S/N: CJZ1-Up
Use commercially available window cleaning
solutions in order to clean the windows. Clean the
outside of the windows from the ground, unless
handholds are available.
Illustration 331
g00566124
Typical example
172
Maintenance Section
Windows - Clean
Cleaning Methods
Aircraft Windshield Cleaner
Apply the cleaner with a soft cloth. Rub the window
with moderate pressure until all the dirt is removed.
Allow the cleaner to dry. Wipe off the cleaner with a
clean soft cloth.
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