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MAINTENANCE INTERVALS - Safety

1. g01029139 Illustration 111 1 Position one final drive so that the oil fill drain plug is at the bottom Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage 2 Remove the oil fill drain plug Allow the oil to drain into a suitable container 3 Clean the plug and inspect the O ring seal If wear or damage is evident replace the oil fill drain plug and or the O ring seal 4 Install the oil fill drain plug 5 Rotate the final drive so that the oil fill drain plug is horizontal 6 Fill the final drive to the bottom of the opening on the oil fill drain plug See Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Capacities Refill 7 Install the oil fill drain plug 8 Perform Step 1 to Step 7 on the other final drive Use a different container for the oil so that the oil samples from the final drives will be separate 9 Completely remove the oil that has spilled onto surfaces 10 Start the engine Operate the machine in the FORWARD direction and in the REVERSE direction 88 Maintenance Section Final Drive Planetary Axle Oil Level Check KEBU7519 08 11 Apply the parking brake 12 Stop the engine Check the oil level 13 Check the drained oil for metal chips or for particles If there are a
2. 99 Every 50 Service Hours or Weekly Cab Air Filter Clean Replace 70 Steering Cylinder Ends Lubricate 100 Tire Inflation Check 100 Every 50 Service Hours or Monthly Fuel Tank Water and Sediment Drain 92 Initial 250 Service Hours Axle Oil Rear Change 67 Final Drive Planetary Axle Oil Change 87 Final Drive Planetary Drum Oil Change 88 Every 250 Service Hours or Monthly Axle Oil Level Rear Check 67 Every 250 Service Hours or 3 Months Belts Inspect Adjust Replace 69 Engine Oil Sample Obtain 85 Final Drive Planetary Axle Oil Level Check 88 Final Drive Planetary Drum Oil Check 89 Isolation Mounts Inspect 96 Vibratory Support Oil Level Check 103 Every 500 Service Hours or 3 Months Cooling System Coolant Sample Level 1 72 reto et RR 74 Every 500 Service Hours or 6 Months Axle Oil Sample Obtain 67 Engine Oil and Filter Change 86 Fuel System Primary Filter Water Separator Replace 5n rete tct te ee ERES 90 Fuel System Primary Filt
3. Illustration 95 g00661129 1 There are two eccentric weight housings The housings are on each side of the drum Perform the following procedure on each housing 2 Drain the oil from the eccentric weight housings 80 Maintenance Section Eccentric Weight Housing Oil Change KEBU7519 08 Illustration 96 900999061 3 Pump 151 L 40 US gal of a suitable hydraulic oil into a 208 L 55 US gal drum PEEL 5 6 7 V E c Y Illustration 97 900684344 1 8C 6875 Connector 2 8B 5774 Reducer Bushing 3 9U 6989 Head 4 99 6983 Filter Element 5 6V 3965 Nipple Assembly 6 8T 4834 Swivel Orifice Tee 7 127 8781 Filter Cart 8 2 4 m 8 ft of 25 mm 1 inch hose 9 3B 6498 Elbow 10 3L 7024 Street Elbow 11 127 0593 Connector 12 3B 7728 Elbow 13 3B 7265 Pipe Nipple 14 940 mm 37 inch of 25 mm 1 inch pipe 4 Use the 127 8781 Filter Cart in order to flush the oil in the 208 L 55 US gal drum Filter the oil for 30 minutes The particle count of the clean oil must be a maximum of ISO 18 13 5 Raise the machine The drum and tires must not be in contact with the ground or the floor Support the machine on stands Refer to the Ope
4. g00997353 Illustration 109 4 Dipstick 10 Before you start the engine check the oil level on dipstick 4 The oil level must be within the FULL RANGE on the dipstick 11 Start the engine Run the engine for two minutes Inspect the machine for leaks Stop the machine 12 Wait for ten minutes in order to allow the oil to drain back into the crankcase Check the oil level Maintain the oil level within the FULL RANGE on the dipstick 13 Close the engine compartment 101897328 Engine Valve Lash Check SMCS Code 1105 535 Note A qualified service person should perform the valve lash check and or the valve lash adjustment Special tools and training are required KEBU7519 08 87 Maintenance Section Engine Water Pump Inspect Refer to your machine s Service Manual for complete instructions 101919752 Engine Water Pump Inspect SMCS Code 1361 040 A water pump that has failed might cause severe engine overheating Severe engine overheating could result in the following problems e Cracks in the cylinder head e Piston seizure e Other potential engine damage Open the engine compartment Illustration 110 900999002 Water pump 1 is located on the engine block at the front of the engine Visually inspect the water pump for leaks If leaks are found all the seals must be replaced 101986436 Final Drive Planetary Axle Oil Change SMCS Code 4050 044 OC
5. Note If you are using Caterpillar antifreeze do not add the supplemental coolant additive at this time 16 Start the engine Run the engine without the cooling system pressure cap until the thermostat opens and the coolant level stabilizes 17 Completely fill the radiator Note The radiator must remain completely full in order for the expansion tank to work properly 18 Replace radiator cap 2 if the gasket is damaged Install radiator cap 2 19 Maintain the level of the coolant to the full line on expansion tank 5 20 Install the cap for expansion tank 6 21 Stop the engine 22 Close the hood for the engine KEBU7519 08 73 Maintenance Section Cooling System Coolant Extender ELC Add 01986272 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL At operating temperature the engine coolant is hot and under pressure Steam can cause personal injury Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand Remove the fill cap slowly to relieve pressure Cooling system conditioner contains alkali Avoid contact with the skin and eyes to prevent personal injury When a Caterpillar Extended Life Coolant ELC is used an Extender must be added to the cooling system Use a 8T 5296 Coolant Test Kit to check the concentration of the coolant Refer to the Special Publication SEBU6250 Caterpillar
6. BZG1 Up SIN DAK1 Up S N ASL1 Up S N TJL1 Up S N ASM1 Up S N DAM1 Up 1 Open the engine compartment The water separator element is located in the engine compartment on the right side of the machine Illustration 118 g00997776 2 Open drain valve 2 Allow the fuel the water and sediment to drain into a suitable container 3 Remove housing 3 from the mounting base 4 Remove the seal for housing 3 5 Remove the filter element from housing 3 6 Install the new filter element into housing 3 7 Install a new seal for housing 3 8 Install housing 3 onto the base 9 Turn the engine start key to the ON position in order to prime the fuel system Check for leaks 10 Close the engine compartment 103338903 Fuel System Primary Filter Water Separator Replace If Equipped SMCS Code 1261 510 1263 510 S N TLH1 Up S N TJL1 Up 1 Open the engine compartment The water separator element is located in the engine compartment next to the fuel tank filler cap Illustration 119 901118416 1 2 Element 3 Glass bowl 4 Sensor connection 5 Drain 6 Bottom cover KEBU7519 08 91 Maintenance Section Fuel System Water Separator Drain 2 Turn the fuel supply valve if equipped to the OFF position 3 Place a suitable container under the water separator Clean the outside of the water separator 4 Open the drain 5 Allow the
7. 121 900896029 2 Lift lever 1 and turn lever 1 counterclockwise until the lever stops Remove the cap 3 Inspect filters 2 Clean the filters Replace the filters if necessary 4 Inspect the O ring seal 3 for damage Replace the seal if necessary 92 Maintenance Section Fuel Tank Water and Sediment Drain KEBU7519 08 900936497 Illustration 122 5 Remove the strainer that is located in the filler opening 6 Wash the strainer and the fuel tank cap in a clean nonflammable solvent 7 Apply a thin film of fuel to the gasket of the fuel tank cap 8 Install the fuel tank cap 01915741 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S 1 Remove the access plate 900997802 Illustration 123 2 The drain valve is located on the bottom of the fuel tank Drain the water and the sediment into a suitable container Refer to the Operation and Maintenance Manual General Hazard Information for information that pertains to containing fluid spillage 3 Close the drain valve Install the access plate Note Dispose of all fluids according to local regulations 101920017 Fuses Replace SMCS Code 1417 510 Fuse The fuses protect the electrical system from damage that is caused by overloaded circuits Change the fuse if the element separates If the ele
8. Machines Fluids Recommendations Cooling System Specifications for more information about the addition of Extender NOTICE Topping off or mixing Cat ELC with other products that do not meet Caterpillar EC 1 specifications reduces the effectiveness of the coolant and shortens coolant service life 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 1 Stop the engine Allow the cooling system to completely cool 2 Open the engine compartment 900997589 Illustration 82 1 Radiator cap 2 Expansion tank 3 Remove the cap for expansion tank 2 4 Add the recommended amount of extender to the coolant system Refer to the Special Publication SEBU6250 Caterpillar Machines Fluids Recommendations Cooling System Specifications for the proper amount 5 Maintain the level of the coolant to the full line on cooling system expansion tank 2 Note The radiator must remain completely full in order for the expansion tank to work properly 6 Install the cap for the expansion tank 2 7 Close the engine compartment 102005238 Cooling System Coolant Level Check SMCS Code 1350 535 FLV 1395 535 FLV At operating temperature the engine coolant is h
9. Obtain an oil sample of the differential oil through the oil level fill plug The oil level fill plug is located on the back side of the rear axle 68 Maintenance Section Backup Alarm Test KEBU7519 08 Refer to the Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information 102855591 Backup Alarm Test SMCS Code 7406 081 The backup alarm is located at the rear of the machine Turn the engine start switch to the ON position in order to perform the test Move the propel control lever to the REVERSE position The backup alarm should start to sound immediately The backup alarm will continue to sound until the transmission control lever is moved to the STOP position or to the FORWARD position Illustration 74 900930005 If the backup alarm does not sound make the necessary repairs immediately Do not operate a machine without a backup alarm 101985706 Battery Clean Check SMCS Code 1401 535 g01028949 Illustration 75 Note The batteries that are supplied with the machines are maintenance free batteries You do not need to check the level of the electrolyte in the maintenance free batteries Check the following items Clean the top of the batteries with a clean cloth Clean the battery terminals Coat the battery terminals with petroleum jelly e Tighten the battery retainers on both of the batteries i00993589 Battery Rec
10. Support Sample Obtain SMCS Code 5656 008 Illustration 154 900999092 Refer to the Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for information on obtaining the oil sample Note After you obtain an oil sample add oil in order to maintain the proper level 104 Maintenance Section Wheel Nuts Tighten KEBU7519 08 01850674 Wheel Nuts Tighten SMCS Code 4210 527 Illustration 155 900942683 Tighten the wheel nuts to a torque of 460 60 340 x 45 Ib ft 01909035 Window Washer Reservoir Fill SMCS Code 7306 544 900994889 Illustration 156 The window washer reservoir is located on the right side of the cab If the level of the cleaning solution is low refill the reservoir 101986422 Window Wiper Inspect Replace SMCS Code 7305 040 7305 510 901029128 Illustration 157 Inspect the front windshield wiper blade and the rear windshield wiper blade If necessary replace the windshield wiper blades 100851568 Windows Clean SMCS Code 7310 070 Use commercially available window cleaning solutions in order to clean the windows Clean the outside of the cab windows from the ground unless handholds are available
11. air filter is located to the left of the seat Illustration 78 g01039169 Remove two hand knobs 1 Remove cover 2 To remove the air filter pull upward on the filter Clean the air filter with a maximum of 200 kPa 30 psi After you clean the air filter inspect the air filter If the air filter is damaged or badly contaminated use a new air filter Install the filter in the reverse order of the previous steps Purge Valves for the Air Conditioning If Equipped LLLI Illustration 79 UNT 2 901029837 The purge valves located in rubber hoses under the cab There is a valve on the left side of the machine and there is a valve on the right side of the machine Squeeze the rubber hose in order to remove any dirt or debris The purge valve may need to be removed from the hose in order to completely remove all of the dirt or debris KEBU7519 08 71 Maintenance Section Circuit Breakers Reset Note If your machine is equipped with side panels the side panels will need to be removed in order to gain access to the purge valves 01909803 Circuit Breakers Reset SMCS Code 1420 529 The circuit breaker panel is located in the engine compartment 900997034 Illustration 80 in order to reset the circuit breaker If the electrical
12. differential level fill plug 2 The differential level fill plug 2 is located on the back right side of the differential case AR Clean differential drain plug 1 and install differential drain plug 1 Clean the drain plug for the axle gear reducer 3 and install the drain plug for the axle gear reducer 3 Add the proper oil to the differential Maintain the level of the oil to the bottom of the hole for the differential level fill plug 2 Refer to the Operation and Maintenance Manual Lubricant Viscosities and Capacities Refill section for more information 5 Clean differential level fill plug 2 and install differential level fill plug 2 101913989 Axle Level Rear Check SMCS Code 3260 535 FLV LL Illustration 72 900996841 Note Always check the oil level when the machine is parked on a level surface Note The differential level fill plug is located on the back side of the rear axle 1 Remove the level fill plug Maintain the oil level to the bottom of the level fill plug opening If necessary add oil Note When you add oil allow the oil to settle in order to verify the oil level 2 Clean the level fill plug Install the plug Axle Oil Sample Obtain SMCS Code 3260 008 LL LU J Illustration 73 900996841
13. drain valve is located on the bottom of the hydraulic oil tank Drain the fluid into a suitable container Note Dispose of the used oil in a proper manner Refer to the Operation and Maintenance Manual General Hazard Information for information that pertains to containing fluid spillage 2 Close the hydraulic oil tank drain valve Remove the hose 3 Refill the hydraulic tank with clean filtered hydraulic oil Refer to the Operation and Maintenance Manual Capacities Refill and Lubricant Viscosities 4 Add the oil through the filler tube 94 Maintenance Section Hydraulic System Oil Filter Replace KEBU7519 08 g01029056 Illustration 127 5 Maintain the oil level between the sight gauges 01914332 Hydraulic System Oil Filter Replace SMCS Code 5068 510 NOTICE Take extreme care to insure the cleanliness of the hy draulic oil Keep the hydraulic oil clean in order to ex tend the component life and assure the maximum per formance age xe Vul 900997060 Illustration 128 1 The filter is located on the left side of the machine The filter is located behind the steps 2 In order to catch any oil that spills place a suitable container under the filter 3 Remove the filter Clean the filter ba
14. element Never at tempt to reuse the secondary filter element by clean ing the element When the primary filter element is replaced the sec ondary filter element should be replaced The secondary filter element should also be replaced if the exhaust smoke is still black 1 Open the access door on the front left side of the machine 2 See Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace Remove the air cleaner cover from the air cleaner housing Remove the primary filter element from the air cleaner housing EY Illustration 103 900101451 84 Maintenance Section Engine Air Filter Service Indicator Inspect KEBU7519 08 3 Remove the secondary filter element 4 Cover the air inlet opening Clean the inside of the air cleaner housing 5 Remove the cover from the air inlet opening 6 Install the new secondary filter element 7 Install the primary filter element 8 Install the air cleaner cover and close the latches securely 9 Close the access door 102012411 Engine Air Filter Service Indicator Inspect SMCS Code 7452 040 1 Open the engine compartment 900996994 Illustration 104 This is the location of the engine air filter service indicator 2 Start the engine Run the engine at high idle If the yellow piston in the engine air filter service indicator enters the red zone service the air cleaner 3 Pr
15. filter elements There are two common methods that are used to clean primary air filter elements e Pressurized air e 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 Illustration 100 g00281692 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 Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the primary air filter element Dirt could be forced further into the pleats 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 KEBU7519 08 83 Maintenance Section Engine Air Filter Secondary Element Replace Inspecting the Primary Air Filter Elements Illustration 101 900281693 Inspect the clean dry primary air filter element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light
16. in the primary air filter element Rotate the primary air filter element Inspect the primary air filter element for tears and or holes Inspect the primary air filter element for light that may show through the filter material If it is necessary in order to confirm the result compare the primary air filter element to a new primary air filter element that has the same part number Do not use a primary air filter element that has any tears and or holes in the filter material Do not use a primary air filter element with damaged pleats gaskets or seals Discard damaged primary air filter elements Storing Primary Air Filter Elements If a primary air filter element that passes inspection will not be used the primary air filter element can be stored for future use Illustration 102 900281694 Do not use paint a waterproof cover or plastic as protective covering for storage An airflow restriction may result To protect against dirt and damage wrap the primary air filter elements in Volatile Corrosion Inhibited VCI paper Place the primary air filter element into a box for storage For identification mark the outside of the box and mark the primary air filter element Include the following information e Date of cleaning Number of cleanings Store the box in a dry location 101822684 Engine Filter Secondary Element Replace SMCS Code 1054 510 SE NOTICE Always replace the secondary filter
17. lubrication system if the recommended procedure is not followed 1 Open the engine compartment 3 g00997115 Illustration 108 Access panels have been removed in order to clearly show the components 1 Drain valve 2 Oil filler cap 3 Filter element 2 Place a suitable container under the drain valve Open drain valve 1 Refer to the Operation and Maintenance Manual General Hazard Information for information that pertains to containing fluid spillage 3 Allow the oil to completely drain 4 Close drain valve 1 5 Remove filter element 3 Note Dispose of the used filter element according to local regulations 6 Clean the filter housing base All of the old filter seal must be removed from the filter housing base 7 Apply a thin coat of engine oil to the seal of the new filter element 8 Install the new filter by hand When the seal contacts the base tighten the filter element for an additional 3 4 turn This will tighten the filter sufficiently Every new oil filter has rotation index marks that are spaced at 90 degree increments Use the rotation index marks as a guide for tightening the oil filter 9 Remove oil filler cap 2 Fill the crankcase with new oil See Operation and Maintenance Manual Capacities Refill See Operation and Maintenance Manual Lubricant Viscosities Clean the oil filler cap and install the oil filler cap
18. machine is not equipped with a battery disconnect switch disconnect the bat tery cables from the battery and tape the battery clamps Place a do not operate tag at the battery discon nect switch location to inform personnel that the machine is being worked on The Crankshaft Vibration Damper is located under the hood on the right side of the machine Illustration 89 900944099 Typical example The Crankshaft Vibration Damper Damage to the crankshaft vibration damper or failure of the crankshaft vibration damper can increase torsional vibrations This can result in damage to the crankshaft and to other engine components A deteriorating damper can cause excessive gear train noise at variable points in the speed range The damper is mounted to the crankshaft on the front of the engine Visually inspect the crankshaft vibration damper for damage Check the bolts for proper tightness Close the hood Refer to the Service Manual or consult your Caterpillar dealer for information about damper replacement 101763534 Drum Cooling Change SMCS Code 6605 044 OC Illustration 90 900902281 Note Clean the area around the fill drain plug before servicing the drum The drum cooling oil requires service when the disassembly of the drum or the assembly of the drum is needed Rotate the fill drain plug to the bottom of the drum Remove the drain plug Pump the oil out of the drum Use the
19. underside buckle Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware If your machine is equipped with a seat belt extension also perform this replacement procedure for the seat belt extension 100 7519 08 Maintenance Section Steering Cylinder Ends Lubricate 01915858 Steering Cylinder Ends Lubricate SMCS Code 4303 086 BD a ie 5 zs nae SS 900997958 Illustration 145 2 Both the lubrication fittings for the rear end of the steering cylinders are located on the left side of the machine Lubricate the fittings for the rear end of the steering cylinders Illustration 143 ERN 3 Raise the steering frame lock pin into the unlocked Lower the steering frame lock pin into the locked position position Note Wipe all of the fittings before you lubricate the bod fittings Tire Inflation Check SMCS Code 4203 535 PX The tire pressure in a warm shop area 18 to 21 C S 65 to 70 F average temperature will significantly v change when you move the machine into freezing temperatures If you inflate the tire to the correct pressure in a warm shop the tire will be underinflated in freezing temperatures Low pressure shortens the life of a tire Wh
20. 98 Every 3000 Service Hours or 2 Years Cooling System Water Temperature Regulator Replace eee La i E ee di dao tu dotes 75 Engine Water Pump Inspect 87 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace 99 Every 3000 Service Hours or 3 Years Eccentric Weight Housing Oil Change 79 Every 6000 Service Hours 3 Years Cooling System Coolant Extender ELC Add 73 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 71 KEBU7519 08 67 Maintenance Section Axle Oil Rear Change 102829504 Axle Oil Rear Change SMCS Code 3260 044 L p 7 5 ULL SUP PA If DoE 2 3 Illustration 71 g01037231 Run the machine and operate the machine for five minutes before you change the oil This will suspend any foreign particles that are present in the oil Running the machine will also provide a more accurate 5 0 5 analysis N Remove differential drain plug 1 The differential drain plug 1 is located on the back side of the differential case near the bottom Remove the drain plug for the axle gear reducer 3 Note Drain the oil into a suitable container Dispose of the used oil in an appropriate manner Remove
21. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR LL Operation and Maintenance Manual CP 533E and CS 533E Vibratory Soil Compactors BZE1 Up Machine TBE1 Up Machine BZG1 Up Machine DAM1 Up Machine SAFETY CAT COM KEBU7519 08 65 Maintenance Section Maintenance Interval Schedule 103646685 Maintenance Interval Schedule SMCS Code 1000 7000 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Note Before each consecutive interval is performed all maintenance from the previous interval must be performed When Required Battery 68 Battery Recycle
22. Operation Manual Daily Inspection for the recommended types of hydraulic oil 3 In order to add the oil remove the filler cap Add the oil through the filler tube Clean the oil filler cap and install the filler cap 102005494 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 5095 008 g00997902 Illustration 131 The sampling port for the hydraulic oil is located on the inlet line for the hydraulic oil filter Refer to Special Publication SEBU6250 S O S Oil Analysis for information that pertains to obtaining a sample of the hydraulic oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the hydraulic oil 101945734 Hydraulic Tank Breather Replace SMCS Code 5056 510 BRE Illustration 132 901012678 1 Open the engine compartment 2 Remove the breather 3 Replace the breather 4 Close the engine compartment i01986289 Indicators and Gauges Test SMCS Code 7450 081 Illustration 133 901029060 1 Look for broken lenses the gauges broken indicator lights broken switches and other broken components in the cab 2 Start the engine 3 Look for inoperative gauges 96 Maintenance Section Isolation Mounts Inspect KEBU7519 08 4 Turn on all machine lights Check for prop
23. ate 2 must not come into contact with the surface of the drum 4 Adjust flexible scraper blades 3 in order to slightly come into contact with the surface of the drum Adjust the flexible scraper blades 3 and backing plate 2 together 5 Tighten bolts 1 Replace the Flexible Scrapers 1 Replace the flexible scrapers if excessive wear or damage is evident 2 Loosen the bolts 1 that are holding flexible scraper blades 3 3 Remove flexible scraper blades 3 Install the new flexible scraper blades Note When you adjust flexible scraper blade 3 the steel backing plate 2 must not come into contact with the surface of the drum 4 Adjust flexible scraper blades 3 in order to slightly come into contact with the surface of the drum Adjust the flexible scraper blades 3 and backing plate 2 together 5 Tighten the bolts and tighten the nuts Padded Drum Scraper Assembly If Equipped Adjust Illustration 92 901011466 There is one scraper that is located in front of the drum There is a scraper that is located at the rear of the drum 1 Inspect the scraper Clean the dirt and the debris from the scraper 2 There are two bolts 4 for each scraper 3 Each scraper is individually adjustable KEBU7519 08 79 Maintenance Section Eccentric Weight Housing Oil Change 3 Slide the scraper 3 toward the drum Adjust the tips so the tips are 25 mm 1 i
24. ater Fill each tire with 430 L 114 US gal of thirty percent calcium chloride and seventy percent water 1 Move the machine to a flat surface and park the machine with the valve stem in the 9 o clock position 2 Remove the cap for the valve stem 3 Check for fluid by depressing the stem in the valve stem The liquid ballast should spray from the stem 4 Move the machine so that the valve stem is in the 11 o clock position 5 Depress the stem in the valve stem A light mist should spray from the valve stem 102 Maintenance Section Vibratory Support Oil Change KEBU7519 08 01915888 Vibratory Support Oil Change SMCS Code 5656 044 OC Illustration 147 900999092 The vibratory support is located on the right side of the drum g00998085 Illustration 148 1 Remove drain plug 1 Drain plug 1 is located on the bottom Drain the oil into a suitable container Dispose of the oil in an acceptable manner Note Refer to Operation and Maintenance Manual General Hazard Information for information that pertains to containing fluid spillage 2 After the oil is drained clean the drain plug Install drain plug 1 Illustration 150 3 Filler plug 2 is located at the top of the support Remove filler plug 2 Note When a machine is equipped with a sensor for the VPM gauge there is a guard over the fi
25. cap for the expansion tank 6 8 Close the hood for the engine 9 Start the engine Run the engine for 90 minutes Stop the engine Allow the cooling system to cool completely 10 Slowly loosen radiator cap 2 and remove radiator cap 2 11 Remove the cap for expansion tank 6 12 Remove bolts 1 in order to allow cooler 3 to swing forward Drain the cleaning solution into a suitable container 13 While the engine is stopped flush the system with water Flush the system until the draining water is transparent 14 Move cooler 3 into position and install bolts 1 Close drain valve 4 NOTICE Mixing Extended Life Coolant ELC with other prod ucts reduces the effectiveness of the coolant and shortens coolant life Use only Caterpillar prod ucts or commercial products that have passed the Caterpillar EC 1 specifications for premixed or con centrate coolants Use only Caterpillar Extender with Caterpillar ELC Failure to follow these recommenda tions could result in the damage to cooling systems components If ELC cooling system contamination occurs refer to Operation and Maintenance Extended Life Coolant ELC under the topic ELC Cooling System Contam ination 15 Add the coolant solution See the following topics Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations Cooling System Specifications Operation and Maintenance Manual Capacities Refill
26. conditions can vary inflate the tires to the following pressures Low Pressure Limit Adjust the tire pressure to the low pressure limit in order to improve traction Lowering the tire pressure will also provide a smoother ride Normal Operating Pressure Adjust the tire pressure to the normal operating pressure when special conditions do not exist High Pressure Limit Adjust the tire pressure to the high pressure limit in order to improve stability Raising the tire pressure will also reduce the flex in the sidewall Maximum Shipping Pressure Adjust the tire pressure to the maximum shipping pressure when you ship the machine Note After shipping the machine return the tire pressure to the correct operating pressure before operating the machine Table 11 PI Low Normal High Maximum Ed Pressure Operating Pressure Shipping 9 Limit Pressure Limit Pressure 8 12 16 16 30 10 12 16 20 30 12 12 16 24 30 14 12 16 28 30 Liquid Ballast The liquid ballast for tires is a solution of water and calcium chloride powder CaCl Calcium chloride powder CaCl is an additive which will provide an antifreeze protection and additional weight If a tire is repaired or replaced the tire must be filled with the correct amount of liquid ballast before the machine returns to operation The correct mixture for the liquid ballast is 300 grams of calcium chloride powder CaCl per 1 Liter of w
27. drain plug opening in order to fill the cavity Install the plug after adding the correct amount of oil The oil will be near the bottom of the opening In order to check the level of the oil rotate the drum so the plug is at the bottom of the drum Remove the plug Maintain the oil to the bottom of the opening Refer to the Operation and Maintenance Manual Lubricant Viscosities and the Operation and Maintenance Manual Capacities Refill 78 Maintenance Section Drum Scrapers Inspect Adjust Replace KEBU7519 08 102839701 Drum Scrapers Inspect Adjust Replace SMCS Code 6607 025 6607 040 6607 510 Smooth Drum Scrapers If Equipped Illustration 91 900930431 Steel Scrapers There is one scraper that is located on the front bumper There is an optional steel scraper for the rear of the drum Adjust Loosen bolts 1 Adjust the steel scraper to 20 mm 0 75 inch to 25 mm 1 inch from the drum surface Flexible Scrapers There is a scraper on the front of the drum and there is a scraper on the rear of the drum Adjust 1 Inspect flexible scraper 2 Clean the flexible scraper of dirt and debris 2 Loosen bolts 1 that are holding the rear flexible scraper blade and the backing plate to the bracket 3 Loosen bolts 1 that hold the front flexible scraper blade and the backing plate to the bracket Note When you adjust flexible scraper 3 steel backing pl
28. e For the correct procedure refer to Air Conditioning and Heating Service Manual SENR5664 or the Disassembly and Assembly Manual for your machine Note A qualified mechanic should replace the components of the refrigerant system since special tooling and training are required 101986313 Rollover Protective Structure ROPS Inspect SMCS Code 7323 040 7325 040 Illustration 140 901007659 Inspect the rollover protective structure ROPS for cracks Inspect the ROPS for any loose bolts or damaged bolts Replace the damaged bolts with original equipment parts only KEBU7519 08 99 Maintenance Section Seat Belt Inspect Note Apply oil to all ROPS bolt threads before you install the bolts Failure to apply the oil to the threads can result in an improper bolt torque Replace the ROPS mounting support if the ROPS rattles Do not straighten the ROPS or repair the ROPS by welding reinforcement plates to the ROPS Consult your Caterpillar dealer for the repair of the ROPS 102429589 Seat Belt Inspect SMCS Code 7327 040 7327 7520 Always check the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine Replace any parts that are damaged or worn before you operate the machine Illustration 141 900932801 Typical example Check the seat belt mounting hardware 1 for wear or for damage Replace any mounting hardware that is
29. e oil level is correct close the engine compartment Add The Engine Oil 1 Remove oil filler cap 1 2 Add the oil so that the oil is at the correct level 3 Clean the oil filler cap Install the oil filler cap 4 Close the engine compartment Engine Oil Sample Obtain SMCS Code 1348 008 Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin 900997051 Illustration 107 Obtain a sample of the engine oil from engine oil sampling valve 1 that is located on the engine oil filter housing Refer to Special Publication SEBU6250 S O S Oil Analysis for information that pertains to obtaining a sample of the engine oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the engine oil 86 Maintenance Section Engine Oil and Filter Change KEBU7519 08 102013243 Engine Oil and Filter Change SMCS Code 1318 510 Run the engine in order to warm up the oil Stop the engine before you drain the oil When the oil is warm the waste particles are suspended in the oil The waste particles will be removed when the oil is drained As the oil cools the waste particles settle to the bottom of the oil pan The waste particles will not be removed if the oil is too cool The waste particles can recirculate through the engine
30. e the engine with a water temperature regulator Depending on load failure to operate with a water temperature regulator could result in either an over heating or an overcooling condition NOTICE If the water temperature regulator is installed incor rectly it will cause the engine to overheat 6 Install a new water temperature regulator Orient the regulator in the same manner as the old regulator Install a new gasket Install the water temperature regulator housing 7 Install the water temperature regulator housing and the hose Tighten the hose clamp 900997605 Illustration 88 8 Add the cooling system coolant Maintain the level of the coolant to the full line on the cooling system expansion tank Note The radiator must be completely full in order for the expansion tank to work properly 9 Inspect cooling system pressure cap and the gasket for damage Replace the pressure cap if the pressure cap or the gasket are damaged 10 Install the cooling system pressure cap 11 Close the engine compartment KEBU7519 08 77 Maintenance Section Crankshaft Vibration Damper Inspect 01900991 Crankshaft Vibration Damper Inspect SMCS Code 1205 040 Accidental machine starting can cause injury or death to personnel working on the machine To avoid accidental machine starting turn the bat tery disconnect switch to the OFF position and re move the key If the
31. eee 68 Battery or Battery Cable Inspect Replace 69 Circuit Breakers 71 Drum Cooling Oil Change 77 Drum Scrapers Inspect Adjust Replace 78 Engine Air Filter Primary Element Clean Replaces nin eer eee ere tta den 81 Engine Air Filter Secondary Element Replace 83 Engine Compartment Clean 84 Fuses Replace 92 Oil Filter renee 97 Radiator Core Clean 98 Wheel Nuts Tighten 104 Window Washer Reservoir Fill 104 Window Wiper Inspect Replace 104 Windows Clean sssseeeeeeeee 104 Every 10 Service Hours or Daily Backup Alarm 68 Cooling System Coolant Level Check 73 Engine Air Filter Service Indicator Inspect 84 Engine Oil Level Check 85 Fuel System Water Separator Drain 91 Hydraulic System Oil Level Check 94 Indicators and Gauges 95 Neutral Start Switch Test 96 Seat Belt Inspect
32. eive the full effect of analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant Complete the information on the label for the sampling bottle before you begin to take the samples Keep the unused sampling bottles stored in plastic bags Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from expansion bottles Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 101914348 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate ma
33. en you operate the machine in freezing temperatures see Operation and Maintenance Manual SEBU5898 Cold Weather Recommendations Illustration 144 1 There are two steering cylinders One steering cylinder is on the right side of the machine and one steering cylinder is on the left side of the machine Lubricate the front lube fitting on each side of the machine Illustration 146 901029115 KEBU7519 08 101 Maintenance Section Tire Inflation Check Tire Inflation Pressure The liquid ballast in tires is an irritant Protect the eyes and face from the spray that comes out of the valve stem when checking the ballast level in the tires or when checking the tires air pressure Failure to protect the eyes and face could result in personal injury The tires are filled with liquid ballast from the factory When you check the tire pressure move the machine so that the valve stem for the tire is in the twelve o clock position in order to prevent the liquid ballast from spraying out of the valve stem Use 1P 0545 Pressure Gauge for tires that are equipped with a liquid ballast Note There will be a slight amount of liquid ballast in the valve stem after moving the machine into position Depress the valve stem in order to allow the liquid ballast to be blown out of the valve stem before attaching the pressure gauge Tire Operating Pressures Since operating
34. er Water Separator jer 90 Hydraulic System Oil Sample Obtain 95 Parking Brake Check 97 Every 1000 Service Hours or 1 Year Axle Oil Rear Change 67 Cooling System Pressure Cap Clean Replace 75 Engine Mounts Inspect 84 Engine Valve Lash 86 Final Drive Planetary Axle Oil Change 87 Final Drive Planetary Axle Oil Sample Obtain 88 Final Drive Planetary Drum Oil Change 88 Final Drive Planetary Drum Oil Sample ODIAN veristen ase ptt 89 Fuel Tank Cap Filter and Strainer Replace Clean 91 Hydraulic System Oil Change 93 Hydraulic System Oil Filter Replace 94 Hydraulic Tank Breather Replace 95 Rollover Protective Structure ROPS Inspect 98 Vibratory Support Oil Change 102 66 Maintenance Section Maintenance Interval Schedule KEBU7519 08 Vibratory Support Oil Sample Obtain 103 Every 2000 Service Hours or 2 Years Crankshaft Vibration Damper Inspect 77 Every Year Cooling System Coolant Sample Level 2 GODT D TT 74 Refrigerant Dryer Replace
35. er operation 5 Stop the engine Note When the engine is stopped and the engine start switch key is turned to the ON position all of the indicator lights should illuminate If the indicator lights do not illuminate replace the lights 6 Make any repairs that are required before operating the machine 102010895 Isolation Mounts Inspect SMCS Code 5654 040 900997915 Illustration 134 Inspect the isolation mounts for damage cracking or splitting If an isolation mount has a crack that is larger than 25 mm 1 0 inch replace the isolation mount If an isolation mount has a crack that is smaller than 25 mm 1 0 inch inspect the mount daily Refer to the Disassembly and Assembly for further information on removing and installing the isolation mounts 102012413 Neutral Start Switch Test SMCS Code 1424 025 1424 081 1424 535 The machine may lurch forward if the neutral start switch is out of adjustment Be sure the area is clear of all personnel and equipment before per forming this test Illustration 135 900934061 1 Place the propel lever the FORWARD position Sol y amp K gt N Illustration 136 900994345 2 Hold the engine start switch in the START position Slowly move the propel lever toward the STOP position 3 If the engine starts before you move the propel lever to the STOP position the neutral start swi
36. es or the batteries as needed 11 Reverse the above steps in order to reconnect the batteries 12 Connect the battery cable at the battery disconnect switch 13 Install the battery disconnect switch key 14 Install the battery compartment covers 15 Turn the battery disconnect switch to the ON position 101909555 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Your engine is equipped with a fan drive belt and with accessory drive belts Your engine is also equipped with an alternator belt For maximum engine performance and maximum utilization of your engine inspect the belts for wear and for cracking Check the belt tension Adjust the belt tension in order to minimize belt slippage Belt slippage will decrease the belt life Belt slippage will also cause poor performance of the alternator and of any driven equipment If new belts are installed recheck the belt adjustment after 30 minutes of operation If two belts or more are required for an application replace the belts in belt Sets If only one belt of a matched set is replaced the new belt will carry more load This is due to the fact that the older belts are stretched The additional load on the new belt could cause the new belt to break Open the engine compartment 900995076 2 3 Compressor mounting bolt 4 Compressor mounting bolt 5 Compressor bracket mounting bolt 70 Maintenance Secti
37. ess the end of the indicator in order to reset the indicator after the air cleaner has been serviced Note See the Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace See the Operation and Maintenance Manual Engine Air Filter Secondary Element Replace 4 Close the engine compartment 101404793 Engine Compartment Clean SMCS Code 1000 070 NOTICE Before spraying the engine compartment with high pressure water turn off the engine and allow the en gine to cool Do not spray water directly on a hot fuel injection pump or damage may occur Use a commercially available engine degreaser in order to clean the engine compartment Use caution and minimize the water around bearings and electrical connections 102213902 Engine Mounts Inspect SMCS Code 1152 040 Engine vibration can be caused by improper mounting of the engine Engine vibration can be caused by loose engine mounts or deteriorated engine mounts 1 Open the engine compartment Illustration 105 901117287 2 Inspect the engine mounts for deterioration 3 Replace any engine mount that is deteriorated 4 Inspect the engine mounts for correct bolt torque 5 Tighten the mounts if the mounts are loose 6 Close the engine compartment KEBU7519 08 85 Maintenance Section Engine Oil Level Check 102012412 Engine Oil Level Check SMCS Code 1348 535 FLV NOTICE Do not under fill or over
38. etary is located on the left side of the drum Note When you add oil to the planetary gearbox wait for a minute before you check the oil level The oil in the planetary gearbox must settle in order to obtain an accurate measurement 4 Fr L4 4 1 SS e OQ Uis C Pa D x S 7 ge be t 0 0 Br 2 2 900998441 Illustration 116 1 Remove level check plug 2 Check the level of the oil in the planetary Maintain the level of the oil at the bottom of the opening for level check plug 2 2 If the oil level is low remove filler plug 1 3 Add oil in order to maintain the oil level 4 Clean plugs 1 and 2 Install plugs 1 and 2 101915674 Final Drive Planetary Drum Oil Sample Obtain SMCS Code 4050 008 5655 008 UA ES OAK 4006 900998449 Illustration 117 Obtain the sample according to the Operation and Maintenance Manual Maintenance Interval Schedule 90 Maintenance Section Fuel System Primary Filter Water Separator Replace KEBU7519 08 Refer to the Operation and Maintenance Manual General Hazard Information for information that pertains to containing fluid spillage Refer to the Special Publication SEBU6250 S O S Oil Analysis for more information 102977542 Fuel System Primary Filter Water Separator Replace SMCS Code 1261 510 1263 510 SIN BZE1 Up SIN TBE1 Up S N
39. fill engine crankcase with oil Either condition can cause engine damage Stop the engine in order to check the oil level DO NOT check the oil level when the engine is running Park the machine on a level surface 1 Open the engine compartment 900997702 Illustration 106 2 Remove dipstick 2 Wipe the dipstick with a clean cloth Insert the dipstick Remove the dipstick and note the oil level Insert the dipstick Note Refer to the Operation and Maintenance Manual Lubricant Viscosities for more information on the correct grade of engine oil to use Refer to Operation and Maintenance Manual Capacities Refill for the correct amount of oil that is used when the oil is changed The correct amount of oil determines the correct level of the oil in the FULL range on the dipstick NOTICE Do not overfill the crankcase The oil level must not reach the top of the FULL range mark or above the FULL range mark 3 Maintain the oil level on the dipstick between the FULL RANGE mark and the ADD OIL mark Add cil if the oil level is too low Note Operating your engine with the oil level above the FULL mark in the FULL Range could cause the crankshaft to dip into the oil This could result in excessively high operating temperatures The high operating temperatures could result in reduced lubricating characteristics of the oil This could cause damage to the bearings and loss of engine power 4 If th
40. fluid to drain into the container 5 Tighten the drain 5 by hand pressure only 6 Hold the element 2 and remove the screw 1 Remove the element and the glass bowl 3 from the base Discard the old element 7 Clean the glass bowl 4 Clean the bottom cover 6 8 Install the new O ring seal Install the bottom cover onto the new element Install the assembly onto the base 9 Install the screw 1 and tighten the screw to a torque of 8 6 Ib ft 10 Remove the container and dispose of the fuel safely 11 Open the fuel supply valve 12 Prime the fuel system 01915686 Fuel System Water Separator Drain SMCS Code 1263 543 1 Open the engine compartment 2 The water separator is located in the engine compartment on the right side of the machine 900997764 Illustration 120 3 Open drain valve 1 that is located on the bottom of the separator element Allow the water and sediment to drain into a suitable container 4 Close drain valve 1 5 f the engine fails to start change the fuel filter If there is a power loss change the fuel filter 6 Close the engine compartment 102626433 Fuel Tank Cap Filter and Strainer Replace Clean SMCS Code 1273 070 Z2 1273 070 STR 1273 510 FI 1 The fuel tank is located on the rear of the machine Open the access door for the fuel tank ala 5 Illustration
41. ings Cycle the oil through the filter for 30 minutes Cycle the oil until the oil is cleaned to a rating of ISO 18 13 or better 11 Install the transfer cart to the housings Pump the oil into the housings Remove the adapter and install the oil fill drain plug For the second cycle repeat steps 9 a through 9 d After the second cycle take an oil sample before filtering the oil No further flushing is necessary if the oil sample cleanliness rating is equal or lower than ISO 18 13 Another flushing is necessary if the oil sample cleanliness rating is higher than ISO 18 13 Note If no further flushing is necessary adjust the oil level so that the housing is filled to the correct oil level 12 When the flushing is complete rotate the drum to the position in order to drain the housings Remove the valve and fitting assembly Drain as much of the oil as possible 13 Rotate the drum until the fill drain plug is at the top Remove the level check plug Fill the drum to the correct level Refer to the Operation and Maintenance Manual Capacities Refill Refer to the Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations Lubricant Information Note The new oil must have a oil sample cleanliness rating that is equal or lower than ISO 18 13 01953476 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY NOTICE Service the air cleaner only with the engine sto
42. ive contains alkali Avoid contact with skin and eyes 3 Slowly loosen radiator cap 2 and remove radiator cap 2 4 Remove the cap for expansion tank 6 72 Maintenance Section Cooling System Coolant ELC Change KEBU7519 08 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the 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 products Dispose of all fluids according to local regulations and mandates 5 Drain valve 4 is located on the bottom corner of the radiator Remove bolts 1 in order to allow cooler 3 to swing forward This will allow easier access to drain valve 4 Open drain valve 4 Allow the coolant to drain into a suitable container 6 Close drain valve 4 Move cooler 3 into position and install bolts 1 Fill the radiator with a solution which consists of clean water and of cooling system cleaner Once the radiator is filled fill the cooling system expansion tank to the full line The concentration of the cooling system cleaner in the solution should be between 6 percent and 10 percent 7 Install radiator cap 2 and the
43. ll port hole The level check plug can be used as a filler plug in this case 4 Level check plug 3 is located on the side of the support Remove level check plug 3 5 Fill the support until the oil is at the bottom of the level check plug opening 3 Refer to the Operation and Maintenance Manual Lubricant Viscosities and Capacities Refill 6 Clean plugs 2 and 3 Install plugs 2 and 3 KEBU7519 08 103 Maintenance Section Vibratory Support Oil Level Check 01915893 Vibratory Support Oil Level Check SMCS Code 5656 535 FLV Illustration 151 900999092 The vibratory support is located on the right side of the drum Illustration 152 1 The level check plug 1 is located at the three o clock position 2 Remove level check plug 1 Check the level of the oil Maintain the level of the oil at the bottom of the level check plug opening COCA t 900999094 Illustration 153 Note When a machine is equipped with a sensor for the VPM gauge there is a guard over the fill port hole The level check plug can be used as a filler plug in this case 3 If the oil level is low remove filler plug 2 4 In order to maintain the proper oil level add oil 5 Refer to the Operation and Maintenance Manual Lubricant Viscosities and Capacities Refill 6 Clean the plugs and install the plugs 101915902 Vibratory
44. ment of the new fuse separates check the circuit Repair the problem before you operate the machine g00999195 Illustration 125 900999196 The compartment for the fuses is located on the right side of the machine There are four screws that hold the cover on the compartment In order to access the compartment for the fuses remove the four screws Remove the cover All of the fuses for this machine are 10 amp 1 Dome Light KEBU7519 08 93 Maintenance Section Hydraulic System Oil Change amp G amp amp G amp amp e m G e 0G 2 Vital Information Management System 3 Ignition System 4 Horn 5 Thermal Starting Aid 6 Backup Alarm 7 Front Work Lights 8 Gauge Lights 9 Circulating Fan 10 Vibratory System 11 Rear Work Lights 12 Parking Brake 13 Spare 14 Spare 15 Front Windshield Wiper Washer 15 Rear Windshield Wiper Washer C3 16 Spare 101986278 Hydraulic System Oil Change SMCS Code 5050 044 5056 044 5095 044 NOTICE Take extreme care to insure the cleanliness of the hy draulic oil Keep the hydraulic oil clean in order to ex tend the component life and assure the maximum per formance Illustration 126 900997073 1 Connect a hose to the hydraulic oil tank drain valve The
45. nch from the surface of the drum Center the scraper between the pads 4 Tighten the bolts Bolle 542 N m 400 Ib ft 102011923 Eccentric Weight Housing Oil Change SMCS Code 6606 044 OC Change the Oil 1 Take an oil sample from each eccentric weight housing There is one eccentric weight housing on each side of the drum No flushing is necessary if the oil sample cleanliness rating is equal or lower than ISO 23 21 The flushing procedure should be performed if an oil sample cleanliness rating is higher than ISO 23 21 Illustration 93 2 Rotate the drum until drain plug 1 is at the bottom of the drum 3 Place a suitable container under the drain plug Remove the drain plug Drain the housing completely Repeat this step for both housings g00999034 Illustration 94 4 Rotate the drum until indicator bar 2 is at the bottom of the drum 5 Remove level check plug 3 Fill the housing with oil Refer to the Operation and Maintenance Manual Lubrication Viscosities and Operation and Maintenance Manual Capacities Refill Maintain the level of the oil to the bottom of the level check opening 6 Clean the plugs Install the plugs 7 Repeat this procedure for the other eccentric weight housing Flush the Housing i Sy EC
46. ny chips or particles consult your Caterpillar dealer 14 Properly dispose of the drained material Obey local regulations for the disposal of the material 01986440 Final Drive Planetary Axle Oil Level Check SMCS Code 4050 535 FLV g01029156 Illustration 112 1 Position the machine so that the oil fill drain plug is horizontal Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage 2 Remove the oil fill drain plug 3 Check the oil level The oil should be near the bottom of the oil fill drain plug 4 Add oil through the oil fill drain plug if necessary Note Do not overfill the final drive 5 Clean the oil fill drain plug Inspect the O ring seal Replace the O ring seal if the O ring seal is worn or damaged 6 Install the oil fill drain plug 7 Repeat the procedure for the other final drive 101986445 Final Drive Planetary Axle Oil Sample Obtain SMCS Code 4050 008 Illustration 113 901029156 Obtain the oil sample when you change the oil Refer to the Operation and Maintenance Manual General Hazard Information for information that pertains to fluid spillage Refer to the Special Publication SEBU6250 S O S Oil Anal
47. on Cab Air Filter Clean Replace KEBU7519 08 Alternator Belt 1 To check the belt tension apply 110 N 25 Ib of force midway between the pulleys Correctly adjusted belts will deflect 14 to 20 mm 1 2 to 3 4 inch 2 In order to adjust the alternator belt loosen bracket bolt 2 and mounting bolt 1 on the alternator bracket 3 To achieve the correct adjustment move the alternator inward or move the alternator outward as required 4 Tighten mounting bolt 1 and bracket bolt 2 Air Conditioner Belt If Equipped 1 Stop the engine in order to inspect the air conditioner belt 2 Inspect the condition of the air conditioner belt and the adjustment of the air conditioner belt The air conditioner belt should deflect 14 to 20 mm 0 55 to 0 79 inch under 110 N 25 Ib of force 3 Loosen compressor mounting bolts 3 and 4 Loosen compressor bracket mounting bolt 5 4 Move the compressor until the correct belt tension is reached 5 Tighten compressor bracket mounting bolt 5 Tighten compressor mounting bolts 3 and 4 6 Recheck the belt deflection If the amount of deflection is incorrect repeat Step 3 to Step 5 7 Startthe engine If poor cooling is still experienced turn off the air conditioner Stop the engine Notify your Caterpillar dealer for air conditioner system service 01986269 Cab Air Filter Clean Replace If Equipped SMCS Code 7342 070 7342 510 The cab
48. on a regularly scheduled basis could cause se vere engine damage Note If you are only replacing the water temperature regulator drain the cooling system coolant to a level that is below the water temperature regulator housing 1 Open the engine compartment Illustration 87 At operating temperature the engine coolant is hot and under pressure Steam can cause personal injury Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand Remove the fill cap slowly to relieve pressure Cooling system conditioner contains alkali Avoid contact with the skin and eyes to prevent personal injury 2 Remove radiator cap 1 in order to relieve the pressure in the cooling system 3 Loosen hose clamp 2 and remove hose 3 from water temperature regulator housing 4 4 Remove bolts 5 from water temperature regulator housing 4 and remove water temperature regulator housing 4 5 Remove the gasket and remove the water temperature regulator from the water temperature regulator housing Make a note of the orientation of the old regulator NOTICE The water temperature regulators may be reused if the water temperature regulators are within test specifica tions are not damaged and do not have excessive buildup of deposits NOTICE Since Caterpillar engines incorporate a shunt design cooling system it is mandatory to always operat
49. osition The blade if equipped is raised The parking brake is engaged The machine is positioned on the specified slope Personal injury can result if the machine moves while testing If the machine begins to move release the parking brake and use the propel lever in order to move the machine to a level surface 5 Park the machine on a level surface If your machine is equipped with a leveling blade lower the leveling blade to the ground 6 Stop the engine NOTICE If the machine moved during the brake test consult your Caterpillar dealer The dealer must inspect the brake system and make any necessary repairs before the machine is returned to operation 01829953 Radiator Core Clean SMCS Code 1353 070 KO Open the engine compartment The radiator core is located at the rear of the machine Illustration 139 900101939 Inspect the radiator core for debris If necessary clean the radiator Compressed air is preferred but high pressure water or steam can be used to remove dust and general debris from a radiator Clean the radiator according to the condition of the radiator Note High pressure water can bend the oil cooler and the radiator fins See Special Publication SEBD0518 Know Your Cooling System for more information about cleaning radiator fins Close the engine compartment 102977292 Refrigerant Dryer Replace SMCS Code 7322 510 7322 710 Referenc
50. ot and under pressure Steam can cause personal injury Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand Remove the fill cap slowly to relieve pressure Cooling system conditioner contains alkali Avoid contact with the skin and eyes to prevent personal injury 74 Maintenance Section Cooling System Coolant Sample Level 1 Obtain KEBU7519 08 1 Open the engine compartment 901037151 Illustration 83 2 Maintain the level of the coolant in expansion tank 1 to the level line 3 Close the engine compartment 01914342 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Note Level 1 results may indicate a need for Level 2 Analysis 900997081 Illustration 84 Refer to the Operation and Maintenance Manual Access Doors and Covers for the location of the service points Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to rec
51. pped 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 Illustration 99 900102316 1 Remove cover 1 for the air filter housing 2 Remove primary filter element 2 from the air filter housing 3 Clean the inside of the air filter housing 4 If the machine is equipped with a vacuator valve clean the vacuator valve on the cover for the air filter housing 5 Install a clean primary air filter element Install the cover for the air filter housing Note Refer to Cleaning Primary Air Filter Elements 6 Reset the engine air filter service indicator 7 Close the access door If the yellow piston in the indicator moves into the red zone after starting the engine or the exhaust smoke is still black after installation of a clean primary filter element install a new primary filter element If the piston remains in the red zone replace the secondary element 82 Maintenance Section Engine Air Filter Primary Element Clean Replace KEBU7519 08 Cleaning Primary Air Filter Elements NOTICE Caterpillar recommends certified air filter cleaning ser vices available at participating Caterpillar dealers The Caterpillar cleaning process uses proven procedures to ass
52. ration and Maintenance Manual Additional Messages for the location on jacking up the machine 6 Start the engine Release the parking brake and rotate the drum until the fill drain plug is at the top of the housing Apply the parking brake and stop the engine 7 Remove the plug Install the valve and fitting assembly that is appropriate for your machine Te g00698763 Illustration 98 a Assemble the 126 7187 Adapter 17 into the male end of the 5R 3796 Quick Coupling Assembly 16 Install the adapter into the hole for the oil fill drain plug Assemble the 8T 0198 Seal Connector 15 onto the female end of the quick coupler 8 Fill the housing with 22 L 6 US gal gallons of clean oil Remove the adapter and install the oil fill drain plug 9 Run the first flush cycle a Start the engine Release the brake b Set the travel speed control to low speed In order to rotate the drum move the propel control c Set the vibratory amplitude control to the low position d Turn on the vibratory system Run the vibratory system for 5 seconds Turn off the vibratory system Repeat the cycle for three minutes KEBU7519 08 81 Maintenance Section Engine Air Filter Primary Element Clean Replace Note For each cycle do not run the vibratory system more than 5 seconds e Stop the drum Position the drum in order to drain the housings 10 Install the transfer cart Pump the oil out of the hous
53. s could enter the lubricating system and the particles could cause damage 102009470 Parking Brake Check SMCS Code 4267 535 Note If the machine configuration changes the parking brakes need to be tested Check the area around the machine Make sure that the machine is clear of personnel and clear of obstacles Put the steering frame lock in the UNLOCKED position Fasten the seat belt before checking the parking brake The following tests are used to determine if the parking brake is functional on a specified grade or a specified slope These tests are not intended to measure the maximum brake holding effort Read all of the steps before you perform the following procedure 901039847 Illustration 138 Position the machine on the incline of the slope but near the base of the slope in order to check the parking brake The test position should be 40 percent or a 22 degree slope 1 Start the engine Refer to the Operation and Maintenance Manual Engine Starting for information on starting the engine 2 If your machine is equipped with a leveling blade raise the leveling blade Move the machine into the test position 3 Place the throttle control into the LOW IDLE position 4 Engage the parking brake The machine should not move under the following conditions 98 Maintenance Section Radiator Core Clean KEBU7519 08 The engine is at low idle The propel lever is in the NEUTRAL p
54. se Discard the filter in a proper manner Refer to the Operation and Maintenance Manual General Hazard Information for information that pertains to fluid spillage 4 Coat the gaskets of the new filter with clean oil 5 Install the new filter Hand tighten the filter When the gasket contacts the filter base tighten the filter element for an additional 3 4 turn This will tighten the filter sufficiently The filters have index marks that are spaced at 90 degree intervals Illustration 129 900994340 6 Start the engine Allow the hydraulic to warm Maintain the oil between the sight gauges If necessary add oil Refer to the Operation and Maintenance Manual Capacities Refill Refer to the Operation and Maintenance Manual Lubricant Viscosities 102358955 Hydraulic System Oil Level Check SMCS Code 5056 535 FLV 5095 535 FLV Note Always check the hydraulic oil level when the machine is parked on a level surface 900994340 Illustration 130 1 Observe the level of the hydraulic oil in the sight gauges The bottom sight gauge must be full The top sight gauge should be no more than half full 2 If necessary add oil KEBU7519 08 95 Maintenance Section Hydraulic System Oil Sample Obtain Refer to the
55. ssure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes 3 Remove the cooling system pressure cap slowly in order to relieve pressure 4 Inspect the cooling system pressure cap for foreign material for deposits and for damage Clean the cooling system pressure cap with a clean cloth If the cooling system pressure cap is damaged replace the cooling system pressure cap 5 Install the cooling system pressure cap 6 Close the engine compartment 102005284 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 1393 010 Replace the water temperature regulator on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system The water temperature regulator should be replaced after the cooling system has been cleaned Replace the water temperature regulator while the cooling system is completely drained Replace the water temperature regulator while the cooling system coolant is drained to a level below the water temperature regulator housing 76 Maintenance Section Cooling System Water Temperature Regulator Replace KEBU7519 08 NOTICE Failure to replace the engine s water temperature reg ulator
56. system is functioning properly the button will remain depressed If the button does not remain depressed check the appropriate electrical circuit Repair the electrical circuit if necessary Circuit Breaker Reset Push in the button Main Breaker 1 E Breaker for the Alternator 2 Breaker for the Glow Plugs 3 102005168 Cooling System Coolant ELC Change SMCS Code 1395 044 NL Drain the coolant whenever the coolant is dirty Drain the coolant when foam is observed 1 Stop the engine Allow the cooling system to cool completely 2 Open the hood for the engine Refer to the Operation and Maintenance Manual Acces Doors and Covers for further information Illustration 81 901040615 1 Bolts 2 Radiator cap 3 Cooler 4 Drain valve 5 Expansion tank 6 Cap for the expansion tank Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Addit
57. tch requires adjustment Do not operate the machine until the repairs have been made Refer to the service manual for your machine for instructions on adjusting the neutral start switch KEBU7519 08 97 Maintenance Section Oil Filter Inspect 102106227 Oil Filter Inspect SMCS Code 1308 507 3004 507 3067 507 5068 507 Inspect a Used Filter for Debris Illustration 137 900100013 The element is shown with debris Use a filter cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can indicate a possible failure If metals are found in the filter element a magnet can be used to differentiate between ferrous metals and nonferrous metals Ferrous metals can indicate wear on steel parts and on cast iron parts Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings rod bearings or turbocharger bearings 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 Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings to the crankshaft and to other parts This can result in larger particles in unfiltered oil The particle
58. ure consistent quality and sufficient filter life Observe the following guidelines if you attempt to clean the filter element Do not tap or strike the filter element in order to re move dust Do not wash the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components The primary air filter element can be used up to six times if the element is properly cleaned and if the element is properly inspected When the primary air filter element is cleaned check for rips or tears in the filter material The primary air filter element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings NOTICE Do not clean the air filter elements by bumping or tap ping This could damage the seals Do not use ele ments with damaged pleats gaskets or seals Dam aged 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
59. worn or damaged Make sure that the mounting bolts are tight Check buckle 2 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect the seat belt 3 for webbing that is worn or frayed Replace the seat belt if the seat belt is worn or frayed Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware Note Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension 102429594 Seat Belt Replace SMCS Code 7327 510 7327 Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor 1 2 ofc 4 901152685 Illustration 142 1 Date of installation retractor 2 Date of installation buckle 3 Date of manufacture tag fully extended web 4 Date of manufacture
60. y cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers KEBU7519 08 75 Maintenance Section Cooling System Pressure Cap Clean Replace 900997081 Illustration 85 Refer to the Operation and Maintenance Manual Access Doors and Covers for the location of the service points Obtain the sample of the coolant as close as possible to the recommended sampling interval Supplies for collecting samples can be obtained from your Caterpillar dealer Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 101909533 Cooling System Pressure Cap Clean Replace SMCS Code 1382 070 1382 510 1 Open the engine compartment 900996985 Illustration 86 2 The cooling system pressure cap is on the top of the radiator Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to relieve pre
61. ycle SMCS Code 1401 561 Always recycle a battery Never discard a battery Always return used batteries to one of the following locations A battery supplier An authorized battery collection facility Recycling facility KEBU7519 08 69 Maintenance Section Battery or Battery Cable Inspect Replace 01985707 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1402 040 1402 510 1 Turn the engine start switch to the OFF position Turn all switches to the OFF position 2 Turn the battery disconnect switch to the OFF position Remove the battery disconnect switch key 901028957 Illustration 76 3 The battery compartment is located at the rear of the machine in the engine compartment 4 Remove the covers for the batteries 5 At the battery disconnect switch disconnect the negative battery cable that is connected to the frame Note Do not allow the disconnected battery cables to contact the disconnect switch Do not allow the disconnected battery cables to contact the other cables Do not allow the disconnected battery cables to contact the opposite terminal of either battery 6 Disconnect the negative battery cable at the battery 7 Disconnect the positive battery cable from the battery 8 Remove the positive cable from the starter motor 9 Remove the cable that connects the two batteries together 10 Perform the necessary repairs Replace the cabl
62. ysis 102828383 Final Drive Planetary Drum Oil Change SMCS Code 4050 044 OC 5655 044 OC Illustration 114 900997746 KEBU7519 08 89 Maintenance Section Final Drive Planetary Drum Oil Check Illustration 115 900997747 The final drive planetary is located on the left side of the drum 1 Run the machine and operate the machine for five minutes before you change the oil This will suspend any foreign particles that are present in the oil Running the machine will also provide a more accurate S O S analysis 2 Remove drain plug 1 Drain the oil into a suitable container Dispose of the oil in an acceptable manner Refer to the Operation and Maintenance Manual General Hazard Information for information that pertains to containing fluid spillage 3 After the oil is drained install drain plug 1 4 Remove level check plug 3 and filler plug 2 5 Refer to the Operation and Maintenance Manual Lubricant Viscosities and Capacities Refill 6 Fill the planetary until the oil is at the bottom of level check plug 3 Note After you fill the final drive with oil wait for five minutes Check the oil level If the oil level has lowered add more oil until the oil is at the bottom of level check plug 3 7 Clean plugs 2 and 3 Install plugs 2 and 3 02827177 Final Drive Planetary Drum Oil Check SMCS Code 4050 535 FLV 5655 535 FLV The final drive plan

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