MAINTENANCE INTERVALS - Safety
Contents
1. Illustration 167 900642098 2 Remove fuel tank cap 900642098 Illustration 168 3 Remove the filler screen 4 Wash the filler screen in clean nonflammable solvent Dry the filler screen with pressure air 5 Inspect the cap and the filler screen Replace the cap if the cap is damaged Replace the filler screen if the filler screen is damaged 6 Install the filler screen 7 Apply a thin film of fuel to the gasket of the fuel tank cap 8 Install fuel tank cap 9 Close the engine compartment i01173199 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S Illustration 169 900642111 1 The drain plug is located under the left front side of the machine 900642118 Illustration 170 2 Remove the clamp and the drain plug Allow the water and sediment to drain into a suitable container 89 Maintenance Section Fuses Replace 3 Install the drain plug and tighten the clamp Note Dispose of all fluids according to local regulations i01172231 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 element of the new fuse separates check the circuit Repair the problem before you operate the machine NOTICE Replace fuses with the same type and size Improp er use of fuses could result in electrical damage Fre2. Illustration 196 900645892 Use engine oil in order to clean the throttle linkage Use engine oil in order to lubricate the throttle linkage Close the engine access cover i01173643 Steering Cylinder Ends Lubricate SMCS Code 4303 086 BD as 900645908 Illustration 197 97 Maintenance Section Throttle Control Lubricate Illustration 198 900645962 The steering cylinder is located in the pivot area The steering cylinder is on the right side of the engine compartment Clean all of the fittings before servicing Clean all of the caps before servicing Clean all of the plugs before servicing Lubricate the fitting at each end of the steering cylinder i01175630 Throttle Control Lubricate SMCS Code 1265 086 900647931 Illustration 199 1 Open the engine access cover 2 Clean the throttle control linkage with a clean rag 3 Lubricate the throttle control linkage with engine oil 4 Close the engine access cover i01254240 Tire Inflation Check SMCS Code 4203 900668495 Illustration 200 If necessary inflate the tires For normal operating conditions inflate the tires to the proper pressure e The proper pressure for the CB 225D is 260 kPa 38 psi The tire inflation pressure is based on the weight of a machine that is ready to work and the machine is without attachments The pressure is based on the rated payload and in average operating conditions
3. quent replacement of fuses may indicate another type of electrical problem Contact your Caterpillar dealer 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 i g00640358 Illustration 171 Oil Cooler Fan 1 15 amp Brake and Neutralizer 2 10 amp Gauges and Horn 3 10 amp Vibratory System and Flow Divider 4 If Equipped 10 amp i Illustration 172 900640381 Flashers 5 10 amp Keyswitch 6 10 amp Backup Alarm and Beacon Light 7 If Equipped 10 amp Emulsion Spray System 8 If Equipped 10 amp Water Spray System 9 10 amp i01173639 Hydraulic Oil Cooler Clean SMCS Code 1374 070 900644941 Illustration 173 1 Lift the engine access cover 90 Maintenance Section Hydraulic System Oil Change Illustration 174 900644962 2 Inspect the condition of the oil cooler Clean the oil cooler Compressed air high pressure water or steam can be used Remove debris from the oil cooler 3 Close the engine access cover 101205889 Hydraulic System Oil Change SMCS Code 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 maxi
4. e A battery supplier e An authorized battery collection facility e Recycling facility i01254094 Battery or Battery Cable Replace SMCS Code 1401 510 1402 510 1 Turn the engine start switch to the OFF position Turn all switches to the OFF position Illustration 119 900647091 2 Open the battery compartment 900668469 Illustration 120 3 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 4 Disconnect the negative battery cable at the battery 71 Maintenance Section Belts Inspect Adjust Replace 5 Disconnect the battery cable from the battery 6 Disconnect the cable from the starter motor 7 Perform the necessary repairs Replace the cables or the battery as needed 8 Reverse the above steps in order to reconnect the battery 9 Install the battery compartment cover 101598238 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Your engine can be equipped with a water pump belt with a fan drive belt and with accessory drive belts Your engine can also be 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 sli
5. 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 1 Stop the engine Allow the cooling system to completely cool 2 Open the engine compartment 900640849 Illustration 128 76 Maintenance Section Cooling System Level Check 3 Carefully loosen the cooling system pressure cap in order to relieve system pressure 4 Open the radiator drain valve Allow some coolant to drain into a suitable container before the sample is taken Excessive sediment can drain away and a more accurate sample results Obtain a sample in an appropriate container Close the radiator drain valve 5 Send the coolant sample to an appropriate lab for analysis See the Special Publication SEBU6250 S O S Coolant Analysis section 6 Refill the cooling system with coolant as required See Special Publications SEBU6250 Cooling System Specifications 7 Tighten the cooling system pressure cap 8 Close the engine compartment 101172277 Cooling System Level Check SMCS Code 1350 535 FLV At operating temperature the eng
6. 1 Year Battery Clean Check sss Battery or Battery Cable Replace Cooling System Pressure Cap Clean Replace Engine Cylinder Head Bolts Check Engine Mounts Inspect ssseseesesess Engine Valve Lash Check n se Hydraulic System Oil Change Hydraulic Tank Breather Replace Hydraulic Tank Strainer Clean Every 3000 Service Hours Eccentric Weight Housing Oil Change Every 3000 Service Hours or 2 Years Cooling System Coolant Extender ELC Add Cooling System Water Temperature Regulator Heplace marenn nde aici cio een teases Every 3 Years Seat Belt Replace sesseess Every 6000 Service Hours or 6 Years Cooling System Coolant ELC Change 69 Maintenance Section Articulating and Oscillating Bearings Lubricate 101598251 Articulating and Oscillating Bearings Lubricate SMCS Code 7057 086 BD 7113 086 BD Articulating Bearings Illustration 113 900645575 The hitch is located in the center pivot area 1 Clean all fittings before servicing 2 Clean all caps before servicing 3 Lubricate the fittings for the articulation bearing Note Use a small amount of grease Excess grease can cause seal damage 4 Install all caps after servicing Oscillating Bearing
7. Move the propel lever to the FORWARD position Hold the engine start switch 2 in the START position Slowly move the propel lever 3 toward the NEUTRAL position 3 If the engine starts before you move the propel lever to the NEUTRAL position the neutral start switch requires adjustment Do not operate the machine until the repairs have been made Consult your Caterpillar dealer for instructions i01719384 Oil Filter Inspect SMCS Code 1308 507 3004 507 3067 507 5068 507 Inspect a Used Filter for Debris Illustration 189 900100013 The element is shown with debris Use a 4C 5084 Filter Cutter or a 175 7546 Oil 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 tha
8. Pressures for each application may vary Consult your Caterpillar dealer for more information about proper tire inflation pressures i01172928 Tire Scraper Inspect Adjust Replace SMCS Code 6607 025 6607 040 6607 510 900646008 Illustration 201 98 Maintenance Section Walk Around Inspection 1 Clean the tire scrapers 1 2 Adjust the tire scrapers 1 3 Replace the tire scrapers if the tire scrapers are damaged 4 Loosen the bolts 2 that fasten the tire scrapers Remove the damaged tire scraper 1 Install the new tire scraper Tighten the bolts on the new tire scraper N o a Adjust the new tire scraper so that the new tire scraper rides just above the tires i01172970 Walk Around Inspection SMCS Code 1000 040 7000 040 NOTICE Accumulated grease or oil on a machine is a fire haz ard Remove this debris with steam cleaning or high pressure water at least every 1000 service hours or at any time there is a significant amount of oil spilled on the machine Note Check the machine for leaks If a leak is found find the source of the leak Repair the leak before you start the machine Check the fluid levels more frequently if you suspect a leak g00642776 Illustration 202 Check the air filter service indicator When the indicator is red service the air filter element 900642781 Illustration 203 Inspect the lights for broken bulbs or broken lenses R
9. drain valve 3 Allow the oil to completely drain 4 Close the drain valve Illustration 157 5 V 900641690 Remove the filter element Discard the used filter element Clean the filter housing base All of the old filter seal must be removed from the filter housing base Apply a thin coat of engine oil to the seal of the new filter element Install the new filter by hand When the gasket contacts the filter 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 Illustration 158 9 900641702 Remove the oil filler plug Fill the crankcase with new oil See Operation and Maintenance Manual Refill Capacities See Operation and Maintenance Manual Lubricant Viscosities Clean the oil filler cap and install the oil filler cap 86 Maintenance Section Engine Valve Lash Check Illustration 159 900641717 Illustration 160 900367841 10 Before you start the engine check the oil level on the dipstick 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 o
10. 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 Contact your Caterpillar dealer for the replacement of the seat belt and 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 each seat belt 101828538 Seat Belt Replace SMCS Code 7327 510 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 each seat belt 96 Maintenance Section Speed and Direction Control Lubricate v o 1 e Illustration 193 900215958 Typical example Contact your Caterpillar dealer for the replacement of the seat belt i01175636 Speed and Direction Control Lubricate SMCS Code 5462 086 5910 086 Illustration 194 900645832 Open the engine access cover 900645888 Illustration 195 Use engine oil in order to clean the linkage for directional control Use engine oil in order to lubricate the directional control linkage
11. manner 6 Clean the parts Inspect the parts for damage Replace the damaged parts or replace the worn parts 7 Clean the filter mounting base All of the old seal must be removed 8 Apply a light coat of diesel fuel to the seal of the new filter 9 Install the new filter Use only your hand for installation of the filter When the gasket contacts the filter base turn the filter by 270 degrees more This will tighten the filter sufficiently Tighten the collar 4 10 Install the bowl 7 and tighten the collar 6 11 Start the engine and check the fuel system for leaks 12 Close the engine compartment 101219595 Fuel System Water Separator Drain SMCS Code 1263 543 Illustration 164 g00649720 1 Lift the engine access cover Illustration 165 g00649727 Note Attach a rubber drain tube to the nozzle from the filter in order to avoid spilling water on the muffler 2 Turn the drain valve counterclockwise in order to open the drain valve 3 Drain the water and the sediment into a suitable container Note Always dispose of drained fluids in accordance with local regulations 4 Close the drain valve 5 Remove the rubber drain tube 6 Close the access cover 88 Maintenance Section Fuel Tank Cap and Strainer Clean i01199496 Fuel Tank Cap and Strainer Clean SMCS Code 1273 070 STR 1273 070 Z2 Illustration 166 900642092 1 Open the engine compartment
12. the dipstick between the MINIMUM mark and the MAXIMUM mark Add oil 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 Add The Engine Oil 1 Open the engine compartment NU Illustration 154 900641674 2 Remove the oil filler plug 3 Add the oll 4 Clean the oil filler plug Install the oil filler plug 5 Close the engine compartment Engine Oil Sample Obtain SMCS Code 1000 008 A WARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Obtain the Sample and the Analysis In addition to a good preventive maintenance program Caterpillar recommends using S O S oil analysis at regular scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine Each oil sample should be taken when the oil is warm and when the oil is well mixed The sample should be taken at this time in order to ensure that the sample is representative of the oil in the crankcase Obtain the S O S Sample Use the following method in order to obtain an S O S sample e Use a 1U 57
13. 138 1 Loosen the bolts and remove the damaged scraper 2 Install the new scraper and tighten the bolts 3 Adjust the scraper in order to touch the drum 4 Adjust the scraper slightly above the tires 80 Maintenance Section Eccentric Weight Housing Oil Change 101599485 Eccentric Weight Housing Oil Change SMCS Code 5622 044 OC 6606 044 OC Illustration 139 900664963 Use water drain hole in order to orient the oil drain hole 900664835 Illustration 140 1 Block drums 1 2 Secure the support with an appropriate strap or chain 2 3 Remove four hoses on hydraulic motor 3 4 Remove five bolts that secure the plate to rubber mounts 4 5 Remove four bolts on support 5 6 Remove the plate and remove motor assembly 6 900664882 Illustration 141 7 Remove five bolts on plate 7 Note Use Caterpillar 4C 9506 Retaining Compound when you reassemble bolts 7 900664862 Illustration 142 8 Remove drain plug 8 9 Drain the oil in a suitable container 10 Clean drain plug 8 11 Rotate the drum by 90 12 Fill the drum to the appropriate level 13 Install the drain plug 14 Reverse the process in order to reassemble the drum 81 Maintenance Section Engine Air Filter Primary Element Clean Replace 101598268 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY NOTICE Do not clean the filter ele
14. 18 Vacuum Pump or use an equivalent pump that is inserted into the sump To avoid contamination of the oil samples the tools and the supplies that are used for obtaining oil samples must be clean Consult your Caterpillar dealer for complete information and assistance in establishing an S O S program for your engine If you fill the engine too fast with oil the oil may saturate the engine breather If the breather is saturated with oil oil will blow out of the breather hose until the breather is free of oil Add the engine oil at a rate of 2 L min 0 5283 US gpm This will help prevent saturating the breather with oil 85 Maintenance Section Engine Oil and Filter Change i01173632 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 lubrication system if the recommended procedure is not followed Illustration 155 900641681 1 Open the engine compartment 900641685 Illustration 156 2 Place a suitable container under the drain hose The drain hose is located below the front frame Open the
15. 3 Refer to Operation and Maintenance Manual Hydraulic System Oil Level Check 13 Install the cap 1 for the hydraulic oil tank 14 Close the engine access cover 101599682 Hydraulic System Oil Filter Replace SMCS Code 5068 510 Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin 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 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 1 Open the engine access cover Illustration 178 900645431 2 The hydraulic oil filter is located on the left side of the machine 900645516 Illustration 179 3 Clean the hydraulic oil filter location 4 Remove the filter with a strap type wrench 5 Clean the filter housing base Remove any existing gasket material 6 Apply a ligh
16. Check 92 Indicators and Gauges Test 93 Neutral Start Switch Test sesuuss 94 Seat Belt Inspect sssssssseess 95 Tire Scraper Inspect Adjust Replace 97 Water Spray System Filter Clean 100 Every 50 Service Hours or Weekly Tire Inflation Check esseeeeseese 97 Every 100 Service Hours or 2 Weeks Fuel System Water Separator Drain 87 Fuel Tank Water and Sediment Drain 88 Speed and Direction Control Lubricate 96 Throttle Control Lubricate susssse 97 Walk Around Inspection esssesse 98 Water Tank Strainer Clean and Inspect 100 Every 250 Service Hours or 3 Months Belts Inspect Adjust Replace 71 Cooling System Coolant Sample Obtain 75 Engine Oil Sample Obtain 84 Engine Oil and Filter Change 85 Fuel System Water Separator Element Replace 86 Steering Cylinder Ends Lubricate 96 Every 500 Service Hours or 6 Months Articulating and Oscillating Bearings Lubricate 69 Hydraulic System Oil Filter Replace 91 Hydraulic System Oil Sample Obtain 92 Every 1000 Service Hours or
17. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATE RP LLAR KEBU7504 02 December 2002 Operation anc Maintenance manual CB 214D CB 224D and CB 225D Vibratory Compactors 1TZ1 Up Machine 8RZ1 Up Machine 9FZ1 Up Machine 68 Maintenance Section Maintenance Interval Schedule i01863142 Maintenance Interval Schedule SMCS Code 1000 7000 When Required Battery Recycle sseess 70 Circuit Breakers Reset ssssssssss 72 Engine Air Filter Primary Element Clean Replace esee 81 Engine Air Filter Secondary Element Replace 82 Fuel Tank Cap and Strainer Clean 88 Fuses Replace eseeeeeee 89 Hydraulic Oil Cooler Clean 89 Oil Filter Inspect eeeseseeeeeeeee 94 Radiator Core Clean ssssssss 95 Water Spray Nozzles Clean sss 99 Water Spray System Drain seisseen 99 Wheel Nuts Tighten seeseeeeeese 101 Every 10 Service Hours or Daily Backup Alarm Test neeese 69 Cooling System Level Check 76 Drum Scrapers Inspect Adjust Replace 79 Engine Air Filter Service Indicator Inspect 82 Engine Oil Level Check seeen 83 Hydraulic System Oil Level
18. d adjust the belt tension Belt slippage will decrease the belt life Belt slippage will delay drum vibration In order to check the belt tension apply 40 N 9 Ib of force to the belt The force must be applied midway between the pulleys The belts will deflect 5 to 6 mm 02 to 24 inch if the belts are adjusted correctly If new belts are installed run the engine for 30 minutes Check the tension of the belt Tighten the belt if the belt is loose Adjust The Vibratory Pump Belt Illustration 124 900664176 In order to adjust vibratory pump belts loosen three mounting bolts 5 In order to tighten the belts turn adjusting bolt 6 clockwise In order to loosen the belts turn adjusting bolt 6 counterclockwise Tighten three mounting bolts 5 i01171492 Circuit Breakers Reset SMCS Code 1420 529 900640492 Illustration 125 in order to reset the circuit breaker If the electrical 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 General Power 1 60 amp Road and Work Lights 2 If Equipped 20 amp 73 Maintenance Section Cooling System Coolant ELC Change 01173766 Cooling System Coolant ELC Change SMCS Code 1395 044 NL A WARNING Personal injury can result from hot coo
19. d 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 When a Caterpillar Extended Life Coolant ELC is used an Extender must be added to the cooling system See the Cooling System Specifications in the Special Publication SEBU6250 for all cooling system requirements Use a 8T 5296 Coolant Test Kit to check the concentration of the coolant For additional information about the addition of Extender see Special Publication SEBU6250 Cooling System Specifications or consult your Caterpillar dealer NOTICE Mixing ELC with other products that do not meet Caterpillar EC 1 specifications reduces the effective ness 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 Caterpillar Extender with Caterpillar 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 75 Maintenance Section Cooling System Coolant Sampl
20. e Obtain 900640666 Illustration 127 3 Slowly loosen the cooling system pressure cap in order to relieve system pressure Remove the cooling system pressure cap 4 If necessary drain enough coolant from the radiator in order to allow the addition of the Extender 5 Add the recommended amount of extender to the coolant system Refer to the Special Publication SEBU6250 Extended Life Coolant ELC for the proper amount 6 Maintain the coolant level to 1 cm of the bottom of the fill pipe 7 Inspect the gasket on the cooling system pressure cap Replace the cooling system pressure cap if the gasket is damaged 8 Install the cooling system pressure cap 9 Close the engine compartment For additional information on the addition of extender see Special Publication SEBU6250 Coolant Recommendations or consult your Caterpillar dealer 101599483 Cooling System Coolant Sample Obtain SMCS Code 1395 008 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 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection
21. e screen Note The water filter for the CB214D and the CB 224 machines is located in the step on the left side of the machine The water filter for the CB 225D machine is located in the step on the right side of the machine Illustration 209 900646201 2 Clean the filter bowl 3 with water or compressed air 3 Clean the screen 2 with water or compressed air 4 Install filter bowl 3 5 Install screen 2 i01173206 Water Tank Strainer Clean and Inspect SMCS Code 5613 571 STR 900646212 Illustration 210 1 Remove the filler cap 2 Remove the strainer 3 Clean the filler cap with clean water or compressed air 4 Clean the strainer with clean water or compressed air 5 Install the strainer 6 Fill the tank with clean water 7 Install the filler cap 101 Maintenance Section Wheel Nuts Tighten 101250213 Wheel Nuts Tighten SMCS Code 4201 527 NT 4210 527 900665858 Illustration 211 Tighten wheel nuts to 165 15 N m 121 7 11 Ib ft
22. e 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 NOTICE Failure to replace the engine s water temperature reg ulator 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 900641121 Illustration 133 1 Open the engine compartment 900641130 Illustration 134 2 Remove the cooling system pressure cap in order to relieve the pressure in the cooling system 3 Remove the water temperature regulator 4 Remove the gasket and remove the water temperature regulator NOTICE Former water temperature regulators may be used if they meet test specifications and are not damaged or have excessive buildup or deposits NOTICE Since Caterpillar engines incorporate a shunt design cooling system it is mandatory to always operate the engine with a water temperature regulator Depending on load failure to operate with a water tem perature regulator could result in either an overheating or an overcooling condition NOTICE If the water temperature regulator is installed inc
23. efer to Operation and Maintenance Manual Refill Capacities for the proper amount Note If you are using CaterpillarLong Life Coolant that contains some additive do not add any supplemental coolant additive at this time Also do not change the coolant conditioner element if you are using CaterpillarLong Life Coolant that contains some additive 12 Take off the cooling system pressure cap Start the engine and run the engine Leave the cap off until the thermostat opens and the coolant level stabilizes 13 Maintain the coolant level to 1 cm of the bottom of the fill pipe 14 Inspect the gasket on the cooling system pressure cap Replace the cooling system pressure cap if the gasket is damaged 15 Install the cooling system pressure cap 16 Close the engine compartment i01599479 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL A WARNING 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 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 prepare
24. eplace the bulbs or the lenses if the bulbs or the lenses are broken Remove any trash in the engine compartment Inspect the cooling system for leaks damaged hoses or trash Repair any leaks Remove any trash from the radiator Inspect the engine attachments for wear or damage Replace any components that are worn or damaged Inspect the hydraulic system for leaks Inspect the following components the hydraulic tank the cylinder rod seals the hoses the lines and the fittings Repair any leaks Repair any damaged components or worn components Inspect the rear axle for any leaks Inspect the tires for damage Check the tires for proper inflation Replace missing valve caps Make sure that all covers and guards are firmly in place Check the guards and covers for damage Inspect the steps walkways and handholds for damage or wear Check the steps walkways and handholds for cleanliness Inspect the Rollover Protective Structure ROPS for damage If repair is necessary consult your Caterpillar dealer Tighten any loose bolts Inspect the operator compartment for cleanliness Keep the operator compartment clean 99 Maintenance Section Water Spray Nozzles Clean i01175290 Water Spray Nozzles Clean SMCS Code 6609 070 9006461 19 Illustration 204 1 Remove the cap from the spray nozzle 2 Remove the screen from the spray nozzle Remove the nozzle from the spray nozzle A Wash t
25. he screen in a clean nonflammable solvent 5 Wash the nozzles in a clean nonflammable solvent 6 Install the screen 7 Install the nozzles 8 Install the caps 9 Rotation of the nozzle may be required in order to establish a correct spray pattern i01175293 Water Spray System Drain SMCS Code 5612 543 The water system must be drained prior to frost or freezing conditions 900646124 Illustration 205 1 Remove the drain plug 1 in order to drain the main water tank 900646126 Illustration 206 Left side step 2 Open the drain cock 2 in order to drain the lines for the spray bar Note On the CB 225 machines the pump for the water spray system is located on the right side of the machine The pump can be accessed through the step on the right side of the machine Use the drain cock that is located by the step on the left side of the machine in order to drain the emulsion tank 900646136 Illustration 207 100 Maintenance Section Water Spray System Filter Clean 3 Access the water filter through the step on the left side Access the water filter through the step on the right side on the CB 225D machine 4 Remove the strainer 5 Allow the water in the water line to drain 6 Clean the strainer 7 Install the strainer i01173028 Water Spray System Filter Clean SMCS Code 5612 070 FI 900646179 Illustration 208 1 Remove filter bowl 1 Remove th
26. il level Maintain the oil level within the FULL RANGE on the dipstick 13 Close the engine compartment 101633611 Engine Valve Lash Check SMCS Code 1105 535 This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life NOTICE Only qualified service personnel should perform this maintenance Refer to the Service Manual or your Caterpillar dealer for the complete valve lash adjust ment procedure Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life 101598322 Fuel System Water Separator Element Replace SMCS Code 1263 510 FQ Illustration 161 g00644804 1 Release the latch for engine cover 2 Lift engine access cover 1 Lift the access cover for the engine The cover must lock in place g00828962 Illustration 162 2 Turn the valve in a counterclockwise direction Drain the fuel into a suitable container Note Dispose of the waste in a proper manner 87 Maintenance Section Fuel System Water Separator Drain 3 Close the valve dL LLLLLLU Illustration 163 900828959 4 Hold bowl 7 while you loosen the collar 6 Remove the bowl 7 and the collar 6 5 Loosen the collar 4 Remove the element 5 Discard the element in a proper
27. imary filter element 6 Close the engine compartment 82 Maintenance Section Engine Air Filter Secondary Element Replace 101598276 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE NOTICE Always replace the secondary filter element Never at tempt to reuse it by cleaning The secondary filter element should be replaced at the time the primary element is serviced for the third time The secondary filter element should also be replaced if the yellow piston in the filter element indicator enters the red zone after installation of a clean primary ele ment or if the exhaust smoke is still black 1 Open the engine compartment 2 Release the spring clips and remove the air cleaner cover 3 Remove the primary element 900664372 Illustration 147 4 Remove the secondary filter 5 Cover the air inlet opening Clean the inside of the air cleaner housing 6 Inspect the gasket between the air inlet pipe and the air cleaner housing Replace the gasket between the air inlet pipe and the air cleaner housing if the gasket is damaged 7 Uncover the air inlet opening Install a new secondary element 8 Install the primary element and the air cleaner housing cover 9 Reset the air filter service indicator 10 Close the engine compartment i01172537 Engine Air Filter Service Indicator Inspect SMCS Code 7452 040 Illustration 148 900641163 1 Open the eng
28. ine compartment access door 2 Start the engine 3 Run the engine at high idle 900641169 Illustration 149 4 If the yellow piston in the engine air filter service indicator enters the red zone service the air cleaner 5 Stop the engine 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 6 Close the engine compartment access door 83 Maintenance Section Engine Cylinder Head Bolts Check i01174213 Engine Cylinder Head Bolts Check SMCS Code 1100 535 BC 900644696 Illustration 150 This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life NOTICE Only qualified service personnel should perform this maintenance Refer to the Service Manual or your Caterpillar dealer for the complete valve lash adjust ment procedure Operation of Caterpillarengines with improper valve adjustments can reduce engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life i01175128 Engine Mounts Inspect SMCS Code 1152 040 900641190 Illustration 151 Open the engine compartment There are three engine mounts There is one engine mount at the front of the engine There are two engine mounts at the
29. ine 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 g00640902 Illustration 129 1 Open the access door on the right side of the machine 900640906 Illustration 130 2 Loosen the radiator filler cap slowly in order to relieve pressure After pressure is relieved remove the radiator cap 3 Maintain the coolant level to 1 cm of the bottom of the fill pipe 4 Inspect the radiator filler cap and the radiator cap seal for damage Clean the cap with a clean cloth or replace the cap 5 Install the cap 6 Close the engine access cover 77 Maintenance Section Cooling System Pressure Cap Clean Replace 101174815 Cooling System Pressure Cap Clean Replace SMCS Code 1382 070 1382 510 A WARNING 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 wi
30. lant 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 Additive contains alkali Avoid contact with skin and eyes 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 NOTICE Do not change the coolant until you read and under stand the material in the Cooling System Specifica tions section 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 Ca
31. ments by bumping or tapping them Do not use filter elements with damaged pleats gaskets or seals Engine damage can result Make sure the cleaned filter elements are completely dry before installing into the filter housing Water re maining in the elements can cause false indications of contamination in Scheduled Oil Sampling test results The filter elements can be cleaned by using the following methods e pressure air e pressure water When you use pressure air the maximum air pressure is 205 kPa 30 psi When you use pressure water the maximum water pressure is 280 kPa 40 psi Illustration 143 900038608 1 When you clean the inside pleats and the outside pleats direct the air along the pleats 2 Inspect the filter elements after you clean the filter elements Do not use a filter if the pleats the gaskets or the seals are damaged 3 Cover the clean filter elements Store the elements in a clean dry location Replace the primary element after the primary element has been cleaned six times Also replace the primary element if the primary element has been in service for one year Remove the Primary Element 1 Open the engine compartment Illustration 144 900641094 2 Open the air filter housing Illustration 145 900641099 3 Remove the primary filter element 900664907 Illustration 146 4 Install tabs 1 in slots 2 5 Reverse the steps in order to install the pr
32. mpartment Illustration 184 900042290 The vent is located on the top of the hydraulic tank Remove the vent from the hydraulic tank Install the new vent Close the engine compartment 101598343 Hydraulic Tank Strainer Clean SMCS Code 5056 070 STR 1 Open the engine compartment 900642332 Illustration 185 2 Remove the hydraulic oil filler cap Pull the screen outward 3 Clean the screen in clean nonflammable solvent Dry the screen with pressure air 4 Install the screen and install the cap 5 Close the engine compartment i01172765 Indicators and Gauges Test SMCS Code 7450 081 900642350 Illustration 186 Look for gauges 1 that are broken Look for indicator lights that are inoperative Look for switches 2 that are broken Start the engine Sound the horn Look for inoperative gauges Turn on all of the machine lights Check for proper operation Stop the engine Make all necessary repairs before you operate the machine 94 Maintenance Section Neutral Start Switch Test Neutral Start Switch Test If Equipped SMCS Code 1424 025 1424 081 A WARNING 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 187 900642400 1 Depress the parking brake knob 1 RN 900642403 Illustration 188 2
33. mum per formance 900645039 Illustration 175 1 Open the engine access cover Illustration 176 900645058 2 Slowly remove the hydraulic tank filler cap 1 in order to relieve the system pressure 3 Remove the hydraulic tank cap 1 Remove the screen 4 Wash the hydraulic tank cap 1 in clean nonflammable solvent Wash the screen in clean nonflammable solvent 5 Check the vent 2 for the hydraulic tank for cleanliness Clean the vent for the hydraulic tank with clean nonflammable solvent 900645106 Illustration 177 Note The hydraulic oil tank drain 4 is located on the left side of the engine compartment A drain hose is connected to the drain on the left side of the frame 6 Open the hydraulic oil drain 4 in order to drain the oil Drain the oil in a suitable container 7 Inspect the inside of the hydraulic tank Clean the inside of the hydraulic tank 8 Remove the suction strainer inside the hydraulic tank Install a new suction strainer in the hydraulic tank 91 Maintenance Section Hydraulic System Oil Filter Replace 9 Close the oil drain 10 Install the screen in the hydraulic tank 11 Refill the hydraulic tank with clean filtered hydraulic oil Refer to the Operation and Maintenance Manual Refill Capacities and Lubricant Viscosities 12 Park the machine on level ground Check the hydraulic oil level The oil level should be visible in the sight gauge
34. or rectly it will cause the engine to overheat 5 Install a new water temperature regulator 6 Add the cooling system coolant Maintain the level of the coolant to 1 cm from the bottom of the fill pipe 7 Inspect cooling system pressure cap and the gasket for damage Replace the pressure cap if the pressure cap or the gasket are damaged 8 Install the cooling system pressure cap 9 Close the engine compartment 79 Maintenance Section Drum Scrapers Inspect Adjust Replace i01171647 Drum Scrapers Inspect Adjust Replace SMCS Code 6607 025 6607 040 6607 510 Inspect Scrapers Illustration 135 900640988 900641016 Illustration 136 1 Remove dirt and debris from scrapers 2 The drum scraper should be adjusted vertical to the ground The drum scraper should be adjusted in order to touch the width of the drum The inner drum scrapers are not adjustable in the same way as the outer drum scrapers The inner drum scrapers can be adjusted with the adjustable spring mounts The adjustable spring mounts are located inside the front and rear frames The tension on the spring mounts should be adjusted in order to prevent bouncing of the tire or the drum scraper when the vibration system is active The tire scrapers should be adjusted slightly above the surface of the tire The scraper should not touch the tire Replace Scrapers Illustration 137 900641022 900641029 Illustration
35. ppage 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 Alternator Belt and Water Pump Belt 900642749 Illustration 121 1 To check the belt tension apply 110 N 25 Ib of force midway between the pulleys Correctly adjusted belts will deflect 13 to 19 mm 1 2 to 3 4 inch 2 In order to adjust alternator belt 1 loosen mounting bolt 3 3 To achieve the correct adjustment move the alternator inward or move alternator 2 outward as required 4 Tighten mounting bolt 3 Note The alternator shaft nut must be tightened to a torque of 50 5 Nem 37 4 Ib ft 5 If new belts are installed check the belt adjustment again after 30 minutes of engine operation at the rated speed Illustration 122 900664176 Close the engine compartment Inspect The Vibratory Pump Belt 900664176 Illustration 123 72 Maintenance Section Circuit Breakers Reset For maximum pump performance inspect belts 4 for wear and for cracking Check the belt tension an
36. rear of the engine Engine vibration can be caused by improper mounting of the engine Engine vibration can be caused by loose engine mounts or deteriorated engine mounts Inspect the engine mounts for deterioration Replace any engine mount that is deteriorated Inspect the engine mounts for correct bolt torque Tighten the mounts if the mounts are loose Close the engine compartment 01599492 Engine Oil Level Check SMCS Code 1348 535 FLV NOTICE Do not under fill or overfill 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 900641670 Illustration 152 2 Remove dipstick 1 Wipe the dipstick with a clean cloth Insert the dipstick Remove the dipstick and note the oil level Insert the dipstick 84 Maintenance Section Engine Oil Sample Obtain Note Refer to the Operation and Maintenance Manual Lubricant Viscosities and 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 Illustration 153 900367841 3 Maintain the oil level on
37. s 900645589 Illustration 114 1 Clean the fitting before servicing 2 Clean the cap before servicing 3 Lubricate the bearing that controls oscillation Note Use a small amount of grease Excess grease can cause seal damage 4 Install the cap after servicing i01169361 Backup Alarm Test SMCS Code 7406 081 900647301 900647297 Illustration 116 The back up alarm 1 is located at the rear of the machine Apply the parking brake Turn the keyswitch ON Move the propel control lever 2 to reverse If the back up alarm does not operate make any needed repairs 70 Maintenance Section Battery Clean Check i01169479 Battery Clean Check SMCS Code 1401 535 Illustration 117 900647091 The battery is located under the engine access cover g00647095 Illustration 118 Note Maintenance free batteries are included with a new machine You do not need to check the electrolyte level in the maintenance free batteries 1 Every 1000 hours tighten the retainers on the battery 1 2 Clean the top of the batteries with a clean cloth for every 1000 hours of operation 3 The battery terminals must be cleaned and coated with petroleum jelly for every 1000 hours of operation 100836435 Battery Recycle SMCS Code 1401 561 Always recycle a battery Never discard a battery Always return used batteries to one of the following locations
38. t coat of hydraulic oil to the gasket on the new filter 7 Use your hand to install the new filter When the seal contacts the base tighten the filter element for an additional three quarters of a turn 92 Maintenance Section Hydraulic System Oil Level Check Illustration 180 900645520 8 With the machine on level ground check the hydraulic oil level in the sight gauge The sight gauge is located on the right side of the machine The oil level should be visible in the sight gauge 9 Add required oil 10 Close the engine access cover i01172713 Hydraulic System Oil Level Check SMCS Code 5050 535 FLV 5095 535 FLV Illustration 181 1 Open the engine compartment g00642185 Illustration 182 g00642189 2 Observe the level of the hydraulic oil in the sight gauge when the oil is warm Maintain the oil level to the mark on the sight gauge 3 If necessary add oil Refer to the Operation and Maintenance Manual Refill Capacities Refer to the Operation and Maintenance Manual Lubricant Viscosities 101175229 Hydraulic System Oil Sample Obtain SMCS Code 5095 008 7542 008 900664339 Illustration 183 Use a oil sample gun or similar equipment to obtain an oil sample from the hydraulic tank 93 Maintenance Section Hydraulic Tank Breather Replace 101598337 Hydraulic Tank Breather Replace SMCS Code 5056 510 BRE Open the engine co
39. t 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 particles could enter the lubricating system and the particles could cause damage 95 Maintenance Section Radiator Core Clean i01172256 Radiator Core Clean SMCS Code 1353 070 KO Illustration 190 900647708 Open the engine compartment The radiator core is located on the left front of the machine Illustration 191 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 See Special Publication SEBDO0518 Know Your Cooling System for more information about cleaning radiator fins Close the engine compartment i01822494 Seat Belt Inspect SMCS Code 7327 040 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 192 900932801 Typical example Check the seat belt mounting hardware 1 for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight Check buckle 2
40. terpillar 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 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 g00640646 Illustration 126 2 Open the engine access cover 3 Slowly loosen the cooling system pressure cap in order to relieve system pressure Remove the cooling system pressure cap 4 Remove the lower hose that is connected to the radiator Allow the coolant to drain into a suitable container 5 Replace the lower drain hose Fill the cooling system with clean water and with a 6 to 10 concentration of cooling system cleaner 6 Start the engine Run the engine for 90 minutes 7 Stop the engine Allow the cooling system to completely cool 8 Remove the lower drain hose from the radiator Drain the cleaning solution 74 Maintenance Section Cooling System Coolant Extender ELC Add 9 Flush the cooling system with water until the draining water is transparent 10 Replace the lower drain hose 11 Add the recommended amount of extender to the coolant system R
41. th 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 g00640920 Illustration 131 1 Open the engine compartment Illustration 132 900640929 2 Remove the cooling system pressure cap slowly in order to relieve pressure 3 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 4 Install the cooling system pressure cap 5 Close the engine compartment Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 1393 010 A WARNING 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 78 Maintenance Section Cooling System Water Temperature Regulator Replace 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 Th
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