Home

MAINTENANCE INTERVALS - Safety

1. Illustration 209 991086387 Illustration 211 901058011 2 Remove bolts 3 on both sides of the 7 Fully insert one of the bolts 5 for the drive frame undercarriage through the bracket and the drive frame Remove the track tensioner Use a suitable pry bar to swing 3 Release the tension on the track Refer to track drive 6 away from the machine Operation and Maintenance Manual Track Rubber Inspect Adjust 4 Remove pins 1 Remove track tensioner 2 A Illustration 212 g01057451 8 Lubricate front idler wheels 7 with a solution of soap and water Use a suitable pry bar to remove Illustration 210 901057441 track 4 5 Use a suitable lifting device to support track 4 The weight of track 4 is approximately 136 kg 300 Ib 6 Use the track tensioner and slide the drive frame forward into the bracket 159 Maintenance Section Track Rubber Remove Replace SEBU7732 09 Installing the Track 287B S N 2 Install the track loosely onto the undercarriage E The first row of drive lugs at the rear portion of the ZSA 944 track should be installed between the rear idler Table 31 wheels Required Tools Tool Part Number Part Description Qty A 180 3033 Repair Stand Set 4 B 242 6165 Track Tool 1 Illustration 215 901083073 3 Remove bolts 9 in order to install Tooling B Removal of bolts 9 which ar
2. g01018171 Illustration 136 3044 engine L 92 971 LEER 4 E ue o e dl g01018203 Illustration 139 3044 engine The sampling port for the engine oil is located on the left side of the engine block Illustration 137 900850465 4 Maintain the oil level to the FULL mark 3 on the dipstick 1 SEBU7732 09 133 Maintenance Section Engine Oil and Filter Change 102742743 Engine Oil and Filter Change SMCS Code 1308 510 1348 044 S N ZSA1 Up S N CYC1 Up S N MDH1 Up 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 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates The normal oil change interval for the machine is Every 500 Service Hours or every year when the following conditions are met e Caterpillar oil API Specification Cl 4 CH 4 or CG 4 multigrade oil is used e Caterpillar filters are used The altitude does not exceed 2300 m 754
3. 1 g01022355 Illustration 141 3044 engine 4 Remove the filter element with a 187 2718 Filter Wrench Refer to Operation and Maintenance Manual Oil Filter Inspect in order to inspect the used filter for debris 134 Maintenance Section Engine Valve Lash Check SEBU7732 09 5 Apply a thin film of clean engine oil to the sealing surface of the new filter element 6 Install a new engine oil filter hand tight until the seal of the engine oil filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the engine oil filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the engine oil filter use the rotation index marks as a guide 7 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter Illustration 142 901018171 3044 engine 8 Remove the oil filler plug 1 Fill the crankcase with new oil See Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Refill Capacities Clean the oil filler plug and ins
4. SMCS Code 1263 543 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 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates The fuel system water separator is located in the left side of the engine compartment 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers Illustration 144 g01023095 Illustration 145 g01023096 2 Loosen the drain valve on the bottom of the water separator Allow the water and the sediment to drain into a suitable container 3 Tighten the drain valve by hand Do not tighten the drain valve with a tool Damage to the valve or to the seals may occur 4 Close the engine access door Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 FQ 1263 510 FQ NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and rep
5. SMCS Code 5095 535 FLV Illustration 159 900956818 Note This film is located near the hydraulic filler cap on machines that are filled with synthetic oil ma od inu OAN i Illustration 160 g00926177 1 Park the machine on level ground 2 Lower the work tool to the ground Turn off the engine 3 Wait for about five minutes before checking the level of the hydraulic oil 4 Maintain the oil level to the middle of the sight gauge Do not overfill the hydraulic tank SEBU7732 09 141 Maintenance Section Lift Arm and Cylinder Linkage Lubricate 101957078 Lift Arm and Cylinder Linkage Lubricate SMCS Code 5102 086 BD 6107 086 BD amma AQUI ADA Illustration 161 Radial Lift Illustration 162 901017361 Extended Reach Apply lubricant to the grease fittings 1 for the lift arm linkage Apply lubricant to the grease fittings 2 for the lift cylinder bearings Repeat the process for the opposite side of the machine 101963869 Lower Machine Frame Clean SMCS Code 7050 070 1 Tilt the cab upward Refer to Operation and Maintenance Manual Cab Tilting Illustration 163 901020241 2 Remove the access panel in the frame that is located underneath the m
6. 9 Remove bolts 9 in order to install Tooling B Removal of bolts 9 which are the retaining bolts for the bogie axle group will release the axle s retainer plate 10 Install Tooling B SEBU7732 09 161 Maintenance Section Track Rubber Remove Replace 11 Lubricate the wheels and the track s drive lugs with a solution of soap and water in order to facilitate installation of the track 12 Pull the handle of Tooling B away from the machine in order to push the track over the rear idler wheels Note Multiple repositionings of Tooling B on the track may be required in order to completely install the track 13 Remove Tooling B Place the axle s retainer plate in position and reinstall bolts 9 Tighten bolts to a torque of 50 10 N m 37 x 7 Ib ft Illustration 222 g01057441 15 Use a suitable lifting device to support the track Install track 4 onto the track drive Illustration 221 901058011 14 Use a suitable pry bar in order to reposition track drive 6 Remove bolt 5 Illustration 223 901086387 16 Place track tensioner 2 in position and install pins 1 17 Install bolts 3 on both sides of the undercarriage 18 Adjust the tension on the track Refer to Operation and Maintenance Manual Track Rubber Inspect Adjust 162 Maintenance Section Track Rubber Remove Replace SEBU7732 09 A Illustr
7. Loader Lift Arm Brace Operation Illustration 111 901019732 2 Remove the filter cover 3 Remove the seal from the cover and inspect the seal If the seal is damaged replace the seal 4 Remove the air filter element from the cover and clean the filter element with low pressure air Replace the element if the element is damaged 5 Install the seal onto the filter cover and install the filter element 6 Install the filter cover on the machine 7 Remove the brace for the loader lift arms and return the brace to the stored position Refer to Operation and Maintenance Manual Loader Lift Arm Brace Operation Recirculation Filter Illustration 112 g01024691 1 Remove the cover in order to access the air filter element 2 Remove the air filter element and clean the element with soap and water Replace the element if the element is damaged 3 Install the element and replace the cover 122 Maintenance Section Circuit Breakers and Fuses Reset Replace SEBU7732 09 102429415 Circuit Breakers and Fuses Reset Replace SMCS Code 1417 510 1420 529 Fuses Fuses protect the electrical system from damage that is caused by overloaded circuits Replace the fuse if the element separates If the element of a new fuse separates check the circuit Repair the circuit if necessary NOTICE Replace the fuses with the same type and size only Otherwise electrical da
8. Every 500 Service Hours or 6 Months Fuel System Primary Filter Water Separator Element Replace cceeceeeeeeeeeeeeeeeeees 135 Hydraulic System Oil Filter Replace 139 Every 500 Service Hours or 1 Year Engine Oil and Filter Change 133 Every 1000 Service Hours Engine Valve Lash Check sssssse 134 Every 1000 Service Hours or 6 Months Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS Inspect 143 Every 1000 Service Hours or 1 Year Bogie and Idler Oil Level Check 119 Sprocket Inspect sss 145 Sprocket Bearings Lubricate 146 Sprocket Bearings Lubricate 146 Every 2000 Service Hours Refrigerant Dryer Replace 143 Every 2000 Service Hours or 1 Year Fuel Injection Timing Check 134 Hydraulic System Oil Change 138 Every 3000 Service Hours or 2 Years Cooling System Water Temperature Regulator Repl ce xndindteostec E etes 127 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace sss 144 Every 5000 Service Hours Engine Crankcase Breather Closed Circuit Replace inet pre 130 Every 6000 Service Hours or 3 Years Coo
9. Reversing the brackets will increase the distance between the idler wheels which results in additional tension on the track See Illustration 192 Note In order to access the brackets refer to the procedure for removing the idler wheels in the Operation and Maintenance Manual Bogie and Idler Inspect Replace Reversing the four 238 7709 Bracket will increase the distance between the idler wheels by 24 mm 0 94 inch After you reverse the brackets and after you reassemble the components for the undercarriage frame check for proper track tension Refer to the procedure Track Adjustment for the 287 153 SEBU7732 09 c oS Os o as 9o a co cc ned Oi g amp oO Track Rubber DETAIL A g01132610 Illustration 192 the four brackets 1 by rotating each bracket by 180 See Detail A Reverse 154 Maintenance Section Track Rubber Remove Replace SEBU7732 09 102125025 Track Rubber Remove Replace SMCS Code 4197 4198 011 4198 510 Removing the Track 247B and 257B Note Refer to the table for the tooling that is needed in order to remove the tracks and install the tracks Table 29 Required Tools Part Number Part Description 224 9415 Kit 1 The Kit includes the Cap the insert and the Installation Tool 1 Position the machine on firm level ground 2 Remove any work tool that is attached to the quick
10. coupler 3 Raise the loader arms and install the brace for the loader lift arm Refer to Operation and Maintenance Manual Loader Lift Arm Brace Operation 4 Use an appropriate floor jack in order to lift the machine off the ground Use appropriate jack stands in order to block up the machine 5 Detension the track Refer to Operation and Maintenance Manual Track Rubber Inspect Adjust g00953660 Illustration 193 6 Remove the snap ring 1 and the dust cover 2 Illustration 194 g00953716 7 Remove the nut 3 and the washer 4 g00953721 Illustration 195 8 Thread the cap onto the end of the axle shaft Note If the cap is not installed the seal on the wheel will be damaged v lt I Illustration 196 g00953723 SEBU7732 09 155 Maintenance Section Track Rubber Remove Replace Illustration 197 g00953730 9 Use a large mallet in order to strike the inside of the track This will cause the wheel bearing to pop out of the wheel The bearing must come out of the wheel in order for the wheel to be removed A pry bar may be needed in order to remove the wheel completely 10 Remove the track Installing the Track 247B and 257B Illustration 198 g00953812 1 Install the cap 4 a e A d d SLSR ay
11. FOPS 2 Note There is a total of four retaining bolts for the ROPS There is a total of eight retaining bolts for the FOPS 2 1 Inspect the ROPS and the FOPS for loose bolts Tighten the bolts 1 to the following torque 125 10 N m 92 7 Ib ft Tighten the bolts 2 to the following torque 55 5 N m 41 4 lb ft Tighten the bolts 3 to the following torque 240 40 N m 177 x 30 Ib ft ROPS and the FOPS for damaged bolts or missing bolts Replace any damaged bolts or missing bolts with original equipment parts only 2 Operate the machine on a rough surface Replace the ROPS mounting supports if the ROPS emits a noise Replace the ROPS mounting supports if the ROPS rattles Do not straighten the ROPS or the FOPS Do not repair the ROPS or the FOPS by welding reinforcement plates to the ROPS or the FOPS Consult your Caterpillar dealer for repair of any cracks in the ROPS or the FOPS Inspect the Flying Object Guard if equipped for damage Consult your Caterpillar dealer for repair of any cracks in the Flying Object Guard 102429589 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 169 900932801 Typical example Check the seat belt mounting hardware 1 for wear or for damage Replace any m
12. batteries to one of the following locations e A battery supplier e An authorized battery collection facility e Recycling facility 101719520 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1401 561 1402 040 1402 510 1 Turn the engine start switch to the OFF position Turn all switches to the OFF position 2 Disconnect the negative battery cable from the starter Note Do not allow the disconnected battery cable to contact the frame of the machine 3 Disconnect the negative battery cable at the battery 4 Perform the necessary repairs Replace the cable or the battery as needed 5 Connect the negative battery cable at the battery 6 Connect the battery cable to the starter of the machine 114 Maintenance Section Belts Inspect Adjust Replace SEBU7732 09 7 Install the engine start switch key Repeat the process for the positive battery cable 101957641 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 If a new belt is installed check the belt adjustment after 30 minutes of operation A belt is considered to be used after 30 minutes of operation 1 Stop the engine in order to inspect the belt 2 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers Illustration 103 901017605 3 Remove the guard for the V belt Illustration 104 901017632 4 Inspect the condition of th
13. conditions oc casional mis feeding is normal If consistent mis feed ing is observed ensure that the track tension is set to the recommended specification If the track tension is set to the recommended specification and mis feed ing is still observed then your application may require a tighter track tension Increase the track tension until consistent mis feeding is no longer observed The intervals for track tension vary depending on the following conditions the machine application the op erator the soil conditions the climate and the condi tion of the undercarriage components Operators are responsible for basic visual inspections of the track tension on a daily basis Track Adjustment for the 247B and 257B Illustration 176 g01031030 1 Place approximately 45 kg 100 Ib between the drive sprocket and the idlers Place a straight edge across the drive sprocket and idlers Measure the track sag between the bottom of the straight edge and the top of the track The track sag should be set at 12 mm 0 5 inch If the track needs adjustment proceed with the following steps SELAA PCR PUR PUR PUR RR PCR PORC PUR PUR RR POR AUR UR 901031032 Illustration 177 2 Loosen the jam nut 1 3 Turn the adjuster 2 in order to raise or lower the drive sprocket Note In order to detension the track for removal fully lower the drive sprocket
14. lubricant to the grease fitting on the horizontal pivot point of the blade Illustration 254 g00648038 Apply lubricant to the grease fitting on the vertical pivot point of the blade Repeat for opposite side of the blade Illustration 255 g00677570 This is a bottom view of the angle blade Apply lubricant to the grease fitting on the pivot point of the cylinder There are five grease fittings Dozer Blade Illustration 256 g01073259 Apply lubricant to the grease fitting on both ends of the right hand angle cylinder 1 Repeat for opposite side of the blade Apply lubricant to the grease fitting on the pivot points on each end of the tilt cylinder 2 There are six grease fittings i01809997 Work Tool Mounting Bracket Inspect SMCS Code 6700 040 BK Illustration 257 900925058 SEBU7732 09 171 Maintenance Section Work Tool Mounting Bracket Inspect Inspect upper angled plate 1 and ensure that the plate is not bent or otherwise damaged Inspect holes 2 for wear and for damage Inspect lower angled plate 3 and ensure that the plate is not bent or otherwise damaged If any wear is suspected or any damage is suspected consult your Caterpillar dealer before you use the work tool
15. new thermostat and a new seal Install the thermostat housing assembly on the engine cylinder head 7 Install the hose Tighten the hose clamp 8 Refill the cooling system See Operation and Maintenance Manual Capacities Refill Refer to Special Publication SEBU6250 Caterpillar Machine Fluid Recommendations for coolant information 9 Close the engine access door 101961088 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY NOTICE Never service the air cleaner when the engine is run ning to avoid engine damage NOTICE Caterpillar recommends certified air filter cleaning ser vices that are available at Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life Observe the following recommendations if you at tempt to clean the filter element Never tap or strike the filter element in order to remove dust Never wash the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must not exceed 206 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 tearing or voiding the pleats Service the air filter elements when the alert indicator for air filter restriction lights Refer to Operation and Maintenance Manual Alert Indicators 1
16. the thermostat on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system Failure to replace the engine s thermostat on a regularly scheduled basis could cause severe engine damage The thermostat should be replaced after the cooling system has been cleaned Replace the thermostat while the cooling system is completely drained or while the cooling system coolant is drained to a level that is below the thermostat housing Caterpillar engines incorporate a shunt design cooling system It is mandatory to always operate the engine with a thermostat 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Drain the coolant from the machine See Operation and Maintenance Manual Cooling System Coolant ELC Change for the procedure to drain the cooling system Illustration 125 901018412 3024 engine 128 Maintenance Section Engine Air Filter Primary Element Clean Replace SEBU7732 09 Peas xA amp ee a Illustration 126 g01018146 3044 engine 3 Loosen the hose clamp 1 and remove the hose from the thermostat housing assembly 2 4 Remove the two bolts 3 from the thermostat housing assembly Remove the thermostat housing assembly 5 Remove the seal and the thermostat from the thermostat housing assembly 6 Install a
17. 02637025 Bogie and Idler Oil Level Check SMCS Code 4159 535 OC 4192 535 OC S N ZSA1 2204 S N CYC1 954 S N MDH1 3315 Note Inspect the seals on the tubes for the bogies and the idlers during the walk around inspection If a seal is leaking replace the seal Note The 267B S N CYC 954 1399 277B S N MDH 3315 4699 and 287B S N ZSA 2205 3999 have sealed bearings The axles are stamped Grease filled The axles are maintenance free If maintenance is required on the idler wheels or on the bogie wheels please refer to your Caterpillar dealer 120 Maintenance Section Bucket Cutting Edges Inspect Replace SEBU7732 09 New axle groups have been released for the following serial numbers 267B S N CYC1400 UP and 277B S N MDH4700 UP The 267B and the 277B use oil in the idler wheel bearings The 267B and the 277B use grease in the bogie wheel bearings The idler wheels have a tag that states Oil filled There is no maintenance interval requirement for these axles If maintenance is required on the axles please refer to your Caterpillar dealer New axle groups have been released for the 287B S N ZSA4000 UP The 287B uses oil in the idler wheels and bogie wheels The axles have a tag that states Oil filled There is no maintenance interval requirement for these axles If maintenance is required on the axles please refer to your Caterpillar dealer Personal injury or death can result from
18. 2509 14 Use a suitable pry bar in order to reposition track drive 6 Remove bolt 5 Illustration 240 g01082508 15 Use a suitable lifting device to support the track Install track 4 onto the track drive ax xj j WRG Illustration 241 901082257 16 Place track tensioner 2 in position and install pins 1 6 9 ey Illustration 242 901082256 17 Move the drive frame rearward until the rear bolts 3 and spacers 8 can be installed in the drive frame Refer to Operation and Maintenance Manual Track Rubber Inspect Adjust Install bolt 3 and spacer 8 on both sides of the undercarriage Tighten bolts to a torque of 215 40 N m 159 x 30 Ib ft 18 Adjust the tension of the track Refer to Operation and Maintenance Manual Track Rubber Inspect Adjust SEBU7732 09 167 Maintenance Section Window Washer Reservoir Fill 19 Install bolt 5 on both sides of the undercarriage Tighten bolts to a torque of 240 40 N m 177 x 30 Ib ft Illustration 243 901057463 Note For detailed instructions about track installation refer to Disassembly and Assembly RENR4884 Track Rubber Remove and Install 20 Remove Tooling A from the machine 101982402 Window Washer Reservoir Fill If Equipped SMCS Code 7306 544 KE NOTICE When operating in freezing temperatures use Caterpillar nonfreezing window washer solvent or
19. 4 Tighten the jam nut to the following torque 270 40 N m 199 x 30 Ib ft 5 Recheck the track tension Track Adjustment for the 267B and 277B HWS X BETREN ANNANN I MIDE E il j HR 900900571 Illustration 178 1 Place approximately 45 kg 100 Ib between the drive sprocket and the track tensioner Place a straight edge across the drive sprocket and the track tensioner Measure the track sag between the bottom of the straight edge and the top of the track The track sag should be set at 12 mm 0 5 inch If the track needs adjustment proceed with the following steps SEBU7732 09 149 Maintenance Section Track Rubber Inspect Adjust Illustration 179 901030181 Stored Position Illustration 180 901090456 Assembled Position 2 Remove the tool that is provided for tensioning the track The tool is stored inside the engine compartment The two parts of the tool must be assembled before the tool can be used UON N 1 Illustration 181 g00899250 3 Install the tool 3 Ratchet the tool in order to remove any pressure that is being placed on the bolts 2 Remove the two bolts lockwashers and locknuts 2 Ratchet the tool in order to pivot the idlers 1 4 Pivot the idlers forward until you are able to reinstall the
20. 5 ft e Sulfur content in the fuel is between 0 05 and 0 50 An oil change interval of Every 250 Service Hours or every six months is required when the following conditions occur e Caterpillar oil API Specification Cl 4 CH 4 or CG 4 multigrade oil is not used e The altitude exceeds 2300 m 7545 ft e Sulfur content in the fuel is between 0 50 and 1 00 An oil change interval of Every 125 Service Hours is required when the following condition occurs e Sulfur content in the fuel is above 1 00 Refer to the results of the S O S oil analysis in order to determine if the oil change interval should be decreased Consult your Caterpillar Dealer for detailed information regarding the optimum oil change interval 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator upward Refer to Operation and Maintenance Manual Radiator Tilting EE SAN ZU 3 A E ma NET Illustration 140 3044 engine Note The crankcase drain is located on the right side of the oil pan 3 Remove the access panel that is located below the drain plug Remove the drain plug and allow the oil to drain into a suitable container Install the drain plug and install the access panel zr C ea S z
21. Ib ft 9 Remove the twelve bolts 4 that retain the drive sprocket to the drive motor Note When you reinstall the bolts 4 tighten the bolts to the following torque 270 40 N m 199 30 Ib ft 900954096 Illustration 207 10 Use a lifting device that is suitable in order to lift the track Lift the track in order to remove the drive sprocket It may be necessary to insert a chock in front of the rear idler in order to prevent the track from spinning as you lift the track 11 Remove the drive sprocket 12 Remove the lifting device from the track The lifting device is not required for removing the track from the machine 13 Grasp the track on top of the drive sprocket Pull the top of the track upward and pull the track to the outside Slide the track past the bogies Lift the track off the front idlers Installing the Track 267B and 277B 1 Follow the steps in reverse order in order to replace the track 2 Tighten the track to the proper tension Refer to Operation and Maintenance Manual Track Rubber Inspect Adjust Removing the Track 287B S N ZSA1 544 Table 30 Required Tools Tool Part Number A 180 3033 Part Description Qty Repair Stand Set 4 or g01057463 Illustration 208 1 Use Tooling A to support the machine 158 SEBU7732 09 Maintenance Section Track Rubber Remove Replace
22. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR SES y 2007 ILL Operation and Maintenance Manual 247B 257B 267B 277B and 287B Multi Terrain Loaders MTL1 5074 247B Machine SLK1 7299 257B Machine CYC1 Up 267B Machine MDH1 Up 277B Machine ZSA1 Up 287B Machine 112 Maintenance Section Maintenance Interval Schedule SEBU7732 09 102743902 Maintenance Interval Schedule SMCS Code 7000 SIN ZSA1 Up S N CYC1 Up S N MDH1 Up When Required Battery Recycle ooo eecececeeseeeeeeeeseeeneeeeeteeeaaees 113 Battery or Battery Cable Inspect Replace 113 Blade Frame Adjust ssesseseess 115 Bucket Cutting Edges Inspect Replace 120 Bucket Tips Inspect Replace 121 Cab Air Filter Clean Replace 121 Circuit Breakers and Fuses Reset Replace 122 Engine Air Filter Primary Element Clean Replace 14 e vena hot ieu 128 Engine Air Filter Secondary Element Replace 129 Fuel System Priming Pump Operate 136 Fuel Tank Cap Clean ees 137 Fuel Tank Water and Sediment Drain 137 Lower Machine Frame Clean 141 Oil Filter Inspect sssseeseeeeee 141 Track Rubber Remove Replace 154 Window Was
23. Open the engine access door 2 The air filter housing is located on the left side of the engine compartment on machines that are equipped with the 3024 engine The air filter housing is located on the right side of the engine compartment on machines that are equipped with the 3044 engine Illustration 127 900891467 SEBU7732 09 129 Maintenance Section Engine Air Filter Secondary Element Replace Illustration 128 g00101864 3 Unlatch the air cleaner housing cover 1 Rotate the cover and remove the cover 4 Remove the primary filter element 2 5 Install a clean filter element into the filter housing and install the cover for the filter housing 6 Close the engine access door 7 Start the engine The alert indicator for air filter restriction should turn off If the alert indicator continues to light replace the secondary air filter Refer to Operation and Maintenance Manual Engine Air Filter Secondary Element Replace 102020796 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE NOTICE Always replace the secondary air filter element Never attempt to reuse it by cleaning The secondary air fil ter 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 alert indi cator for air filter restrict
24. achine 3 Remove any debris or dirt from the inside of the frame 4 Reinstall the access panel and tilt the cab downward 102106227 Oil Filter Inspect SMCS Code 1308 507 3067 507 5068 507 Inspect a Used Filter for Debris Illustration 164 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 142 Maintenance Section Quick Coupler Inspect SEBU7732 09 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 particles could enter the lubricating system and the particles coul
25. ain the bogie or the idler Remove the bogie or the idler Note When you reinstall the bolts on the idler tighten the bolts to the following torque 120 x 20 N m 88 15 Ib ft When you reinstall the bolts on the bogie tighten the bolts to the following torque 50 14 N m 37 x 10 Ib ft 6 Reverse steps in order to reassemble the components Use the special torques that are noted SEBU7732 09 119 Maintenance Section Bogie and Idler Oil Level Check Replacement for the 287B Illustration 109 1 In order to remove a bogie group remove the four bolts lockwashers locknuts 1 and plates In order to remove an idler group remove the four bolts lockwashers 2 and plates An idler group can be removed at this point Note When you reinstall the four bolts 1 and 2 tighten the bolts to the following torque 50 10 N m 37 7 Ib ft 2 Raise the side of the machine so that the bogie group can be removed from the bottom of the undercarriage 3 Remove the bolts lockwashers and locknuts 3 that retain the bogie or the idler Remove the bogie or the idler Note When you reinstall the bolts on the idler tighten the bolts to the following torque 120 20 N m 88 15 Ib ft When you reinstall the bolts on the bogie tighten the bolts to the following torque 50 x 14 N m 37 x 10 Ib ft 4 Reverse steps in order to reassemble the components Use the special torques that are noted g01030397 1
26. air 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 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note This unit has a dual purpose The element serves as a water separator and a fuel filter 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers Ea Illustration 146 g01017292 Fuel Filter Water Separator for the 3024 engine that is located on the left side of the engine compartment 136 Maintenance Section Fuel System Priming Pump Operate SEBU7732 09 Illustration 147 g01017293 Fuel Filter Water Separator for the 3044 engine that is located on the right side of the engine compartment 2 Open the drain on the fuel filter water separator 3 Allow the water and fuel to drain into a suitable container 3 Close the drain valve by hand Do not tighten the drain valve with a tool Damage to the valve or to the seals may occur 4 Support the fuel filter water separator and rotate the locking ring 1 counterclockwise Remove the fuel filter water separator 5 Rotate the lock
27. asures less than the minimum thickness that is listed in the following table replace the ring 146 Maintenance Section Sprocket Bearings Lubricate SEBU7732 09 Table 28 247 257 267 277 and 287 Component Minimum Thickness Sprocket Rings 4 75 mm 0 19 inch 101992415 Sprocket Bearings Lubricate SMCS Code 4164 086 BD 7551 086 JK S N ZSA1 3999 S N CYC1 1399 S N MDH1 4699 S N SLK1 7299 S N MTL1 5074 NOTICE The service interval for the lubrication of the sprock et bearings should be reduced to every 500 service hours if the machine is operated in wet and muddy conditions Illustration 172 g01025225 typical example 1 Use a mallet in order to pound the housing plug inward until the plug falls out of the housing If the plug was damaged during removal replace the plug 2 Wipe the old grease out of the housing 3 Pull out the bearing seal Replace the seal if the seal is damaged 4 Pack the bearing with clean grease and push the seal into position Place clean grease on the outside of the seal in order to protect the seal 5 If the old housing plug is reinstalled reverse the housing plug and pound the plug into the housing 102637639 Sprocket Bearings Lubricate SMCS Code 4164 086 BD 7551 086 JK S N ZSA4000 Up S N CYC1400 Up S N MDH4700 Up Note The bearing requires no maintenance under normal conditions If the machine is used in wet conditio
28. ation 224 19 Remove Tooling A from the machine Removing the Track 287B S N ZSA545 Up Table 32 g01057463 Required Tools Tool Part Number Part Description Qty A 180 3033 Repair Stand Set Illustration 225 1 Use Tooling A to support the machine g01057463 Illustration 226 g01082256 2 Remove bolt 3 and spacer 8 on both sides of the undercarriage Note The track drive may need to be moved forward in order to provide access to bolt 3 on the inside of the track drive Refer to Operation and Maintenance Manual Track Rubber Inspect Adjust 3 Remove bolt 5 on both sides ofthe undercarriage Illustration 227 901081661 4 Loosen the jam nut and turn the adjuster in order to move the drive assembly SEBU7732 09 163 Maintenance Section Track Rubber Remove Replace 6 Illustration 228 90 08229 Illustration 230 g0 1082509 5 Use the track tensioner 2 in order to move the 7 Align the drive frame and the bracket on the track drive forward onto the flat portion of the undercarriage Install bolt 5 Use a suitable pry undercarriage Remove pins 1 Remove track bar to reposition track drive 6 away from the tensioner 2 machine A Illustration 229 901082508 Illustration 231 pierre 6 Use a suitable lifting device to support track 4 8 Lubricate front idler wheels 7 with a solutio
29. aulic C Solenoid 31 Auxiliary Electric Control C1 32 Auxiliary Hydraulic C Solenoid 124 Maintenance Section Cooling System Coolant ELC Change SEBU7732 09 e 35 ECM signal for the Auxiliary Hydraulic C and the Auxiliary Hydraulic C e 36 Auxiliary Electric Control C2 e Diodes e 37 C e 38 C Illustration 115 g01019607 Circuit Breaker The main circuit breaker is located in the engine compartment on the left side Press the switch and release the switch in order to reset the circuit breaker 101961213 Cooling System Coolant ELC Change SMCS Code 1395 044 NL Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure NOTICE Mixing ELC with other products will reduce the effec tiveness of the coolant This could result in damage to cooling system compo nents If Caterpillar products are not available and com mercial products must be used make sure they have passed the Caterpillar EC 1 specification for pre mixed or concentrate coolants and Caterpillar Extender Note The machine was shipped from the factory with Extended Life Coolant ELC in the cooling system For information about the addition of Extender to your cooling system see the Operation an
30. aulic oil is located on the fan motor 101962605 Hydraulic System Oil Change SMCS Code 5095 044 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 Illustration 153 900956818 Note This film is located near the hydraulic filler cap on machines that are filled with synthetic oil Operate the machine for a few minutes in order to warm the hydraulic system oil Personal injury or death can result without releas ing all of the hydraulic pressure Release all the pressure from the hydraulic sys tem before any lines are disconnected The machine should be on level ground Lower the bucket to the ground and apply slight downward pressure Engage the parking brake and stop the engine Keep the armrest lowered Turn the engine start switch key to the ON position Push the parking brake switch Move all of the hydraulic control levers while you press several times on each side of the auxiliary hydraulic control if equipped in o
31. ble Minor damage includes nicks cuts small pieces that are missing and small grooves This minor damage is normal and acceptable Minor damage will not adversely affect machine performance The bogies and the idlers should be replaced when the damage to the rubber wheels adversely affects machine performance Replace the bogies and the idlers when the rubber is worn beyond the minimum specifications that are listed below Note The tubes for the bogies and the tubes for the idlers on the 267B 277B and 287B contain oil Inspect the tubes for leaks If a leak is suspected the oil level should be checked Refer to Operation and Maintenance Manual Bogie and Idler Oil Level Check Table 25 Bogie Wheels and Idler Wheels Wear Limits 247B and 257B Minimum Width Minimum Thickness 254 mm 10 inch 48 mm 1 9 inch 3 mm 0 1 inch 356 mm 14 inch 48 mm 1 9 inch 3 mm 0 1 inch Table 26 Bogie Wheels and Idler Wheels Wear Limits 267B 277B and 287B Minimum Width Minimum Thickness 254 mm 10 inch 32 mm 1 3 inch 3 mm 0 1 inch One Piece Wheel and Two Piece Wheel 356 mm 14 inch 45 mm 1 8 inch 3 mm 0 1 inch One Piece Wheel and Two Piece Wheel SEBU7732 09 117 Maintenance Section Bogie and Idler Inspect Replace Replacement for the 247B and 257B Illustration 107 1 Remove the track Refer to Operation and Maintenance Manual Track Rubber Remov
32. bricant to the grease fitting 1 for the pivot pin of the apron Apply lubricant to the grease fitting 2 for the rod end of the multipurpose bucket cylinder Apply lubricant to the grease fitting 3 for the head end of the multipurpose bucket cylinder Repeat for the other side of the bucket There are six grease fittings Utility Grapple Tools Illustration 247 g00647980 Apply lubricant to the four grease fittings for the grapples Illustration 248 900647988 Apply lubricant to the two fittings for the grapple cylinder There are six grease fittings SEBU7732 09 169 Maintenance Section Work Tool Lubricate Industrial Grapple Tools T Illustration 249 g00645995 Apply lubricant to the four grease fittings for the fork cylinders g00646004 Illustration 250 Apply lubricant to the four grease fittings for the two forks There are eight grease fittings Grapple Rake Illustration 251 g01368386 Apply lubricant to the four grease fittings for the grapple cylinders Apply lubricant to the four grease fittings for the two grapples There are eight grease fittings Angle Blade g00648033 Illustration 252 Apply lubricant to the grease fitting on the rod end of the angle cylinder 170 Maintenance Section Work Tool Mounting Bracket Inspect SEBU7732 09 Illustration 253 g00648037 Apply
33. bucket cutting edges 1 Lower the lift arms fully Tilt back the bucket so that the bucket cutting edge is accessible 2 Place blocks under the raised edge of the bucket 3 Remove the bolts Remove the cutting edge and the end bits 4 Clean the contact surfaces 5 Use the opposite side of the cutting edge if this side is not worn 6 Install a new cutting edge if both edges are worn T Install the bolts 8 Remove the blocks that are under the bucket 9 After a few hours of operation check the bolts for proper torque SEBU7732 09 121 Maintenance Section Bucket Tips Inspect Replace 101764331 Bucket Tips Inspect Replace SMCS Code 6805 040 6805 510 Personal injury or death can result from bucket falling Block the bucket before changing bucket cutting edges 1 Lower the lift arms fully Tilt back the bucket so that the bucket tips are accessible 2 Place blocks under the raised edge of the bucket 3 Remove the mounting bolts Remove the bucket tips 4 Clean the mounting surface 5 Replace the bucket tips 6 Install the bolts 7 Remove the blocks that are under the bucket 8 After a few hours of operation check the bolts for proper torque 101962545 Cab Air Filter Clean Replace If Equipped SMCS Code 7342 070 7342 510 Fresh Air Filter 1 Raise the loader lift arms Install the brace for the loader lift arm Refer to Operation and Maintenance Manual
34. c system Inspect the suction hoses and hose clamps 8 Install the hydraulic tank filler cap 102742828 Hydraulic System Oil Filter Replace SMCS Code 5068 510 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 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates The hydraulic oil filter is located in the engine compartment 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers QOL VLHHEHEEDOER ENEBEBBERBERBER Illustration 157 900926534 2 Remove the hydraulic tank filler cap 140 Maintenance Section Hydraulic System Oil Level Check SEBU7732 09 Illustration 158 g01017252 The hydraulic filter is located on the left side of the engine compartment 3 Remove the filter with a strap type wrench Note Place a suitable nonconductive container under the hydraulic oil filter Use this container in ord
35. cap JEL gt amp g00956179 Illustration 121 Note The sight gauge for the coolant level is located on the right side of the radiator on machines that are equipped with the 3024 engine The sight gauge for the coolant is located on the left side of the radiator on machines that are equipped with the 3044 engine 7 Check the coolant level in the sight gauge on the radiator Maintain the coolant level to the top of the sight gauge with the radiator in the LOWERED position 8 Tilt the radiator guard downward 9 Close the engine access door For additional information on the addition of extender see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations 101959244 Cooling System Level Check SMCS Code 1350 040 HX 1350 535 FLV 1382 070 1382 510 Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator guard upward Refer to Operation and Maintenance Manual Radiator Tilting EEL gt t Illustration 122 g00956179 SEBU7732 09 127 Maintenance Section Cooling System Water Temperature Regulator Replace Note The sight gauge for the coolant l
36. d Maintenance Manual Cooling System Coolant ELC Extender Add or consult your Caterpillar dealer Drain the coolant whenever the coolant is dirty or whenever the coolant is foaming The radiator cap is located under the radiator guard on the top of the engine compartment Allow the machine to cool before you change the coolant 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Raise the radiator guard Refer to Operation and Maintenance Manual Radiator Tilting EEL SAE t Illustration 116 g00956151 Note The radiator cap is located on the left side of the radiator on machines that are equipped with the 3024 engine The radiator cap is located on the right side of the radiator on machines that are equipped with the 3044 engine 3 Slowly loosen the radiator cap in order to relieve system pressure Remove the radiator cap SEBU7732 09 125 Maintenance Section Cooling System Coolant Extender ELC Add l ke rt v LAF SAA c SAC ug MI Ds r Bs A3 I Xe AU Illustration 117 3024 drain valve e ll E Illustration 118 901018862 3044 drain valve 4 Remove the drain plug and allow the coolant to drain into a suitable container 5 Install the drain plug 6 Replace the thermostat See Operati
37. d cause damage 101734746 Quick Coupler Inspect SMCS Code 6129 040 Illustration 165 g00889446 1 Move the quick coupler levers 1 to the disengaged position Ensure that the levers are not bent or broken 2 Check the top edges of the quick coupler assembly 2 for wear or for damage N Illustration 166 900889412 3 Move the quick coupler levers 1 to the engaged position Ensure that the levers move freely without restriction 4 Make sure that the coupler pins 3 extend through the bottom of the quick coupler assembly Check the pins for wear and check the pins for damage 5 Move the quick coupler levers to the disengaged position If any wear is suspected or damage is suspected consult your Caterpillar dealer before you use a work tool 101488851 Radiator Core Clean SMCS Code 1353 070 KO The radiator is located at the rear of the machine above the engine compartment 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator guard upward Refer to Operation and Maintenance Manual Radiator Tilting NOTICE When you are using compressed air or high pressure water to clean the radiator fins ensure that the air or water is directed parallel to the fins If the compressed air or high pressure water is not directed parallel to the radiator fins the radiator fins could be bent or dam aged Note You can use compres
38. diaphragm and the locating ring 5 Clean the cavity for the breather 5 6 Remove the gauze that is located below the cavity for the breather 7 Clean the following items with a clean diesel fuel e Breather e Breather cover e Diaphragm assembly Location ring assembly e Spring e Gauze 8 Allow the parts to dry Pressure air may be used to dry the parts 9 Install the gauze and install the components of the breather Install the breather cover 10 Tilt the radiator downward 11 Close the engine access door 101959002 Engine Oil Level Check SMCS Code 1348 535 FLV NOTICE Do not overfill the crankcase Engine damage can re sult 1 Stop the engine and allow the oil to drain back into the oil pan 2 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 3 Tilt the radiator upward Refer to Operation and Maintenance Manual Radiator Tilting 132 SEBUT7732 09 Maintenance Section Engine Oil Sample Obtain 5 f necessary remove the oil filler cap 2 and add oil 6 Clean the oil filler cap and install the oil filler cap T Tilt the radiator downward 8 Close the engine access door Engine Oil Sample Obtain SMCS Code 1348 554 SM 7542 008 Illustration 135 901018561 3024 engine Illustration 138 901018202 3024 engine
39. e Replace 2 Remove the retaining ring 1 and the dust cap 2 3 Remove the nut 3 and the washer 4 Note When you reinstall the nut 3 tighten the nut to the following torque 168 30 N m 124 22 lb ft 4 Remove the bearing 5 Note When you reinstall the bearing 5 lubricate the bearing with 1P 0808 Multipurpose Grease g01029962 118 Maintenance Section Bogie and Idler Inspect Replace SEBU7732 09 Replacement for the 267B and 277B Zoe Ju Rr Ne Illustration 108 1 Remove the track Refer to Operation and Maintenance Manual Track Rubber Remove Replace 2 In order to remove a bogie group remove the four bolts lockwashers and locknuts 1 In order to remove an idler group remove the four bolts lockwashers 3 and the plates An idler group can be removed at this point Note When you reinstall the four bolts 1 tighten the bolts to the following torque 120 20 N m 89 15 Ib ft When you reinstall the four bolts 3 tighten the bolts to the following torque 95 10 N m 70 x 7 Ib ft 3 Raise the side of the machine so that the bogie group can be removed from the bottom of the undercarriage 4 Remove the four bolts lockwashers 2 and the plates that retain the bogies 900955323 Note When you reinstall the four bolts tighten the bolts to the following torque 95 10 N m 70 x 7 Ib ft 5 Remove the bolts lockwashers and locknuts 4 that ret
40. e belt 1 and the adjustment of the belt The belt should deflect 10 mm 0 39 inch under a straight pull of 44 N 10 Ib This measurement should be taken between the alternator pulley and the crankshaft pulley Note A 144 0235 Borroughs Belt Tension Gauge may be used to measure belt tension This measurement should be taken between the alternator pulley and the crankshaft pulley Refer to the following table for belt tension Table 24 Belt Tension Belt Tension Initial Used 534 22 N 120 5 Ib 400 44 N 90 10 Ib 5 Loosen the mounting bolt 2 Loosen the adjusting locknut 3 6 Move the alternator until the correct tension is reached 7 Tighten the adjusting locknut Tighten the mounting bolt 8 Recheck the belt deflection If the amount of deflection is incorrect repeat step 4 to step 7 9 Install the guard for the V belt 10 Close the engine access door SEBU7732 09 115 Maintenance Section Blade Frame Adjust 102549571 Blade Frame Adjust SMCS Code 6060 025 BG Height Adjustment Illustration 105 901161532 1 Height Adjustment for the Frame 2 Adjusting Bolts 3 Frame The height of the frame may be adjusted in order to compensate for the wear on the cutting edge The front portion of the frame needs to be lowered as the cutting edge wears Remove the bolts 2 and lower the frame 3 Install the bolts This will keep the blade level with t
41. e radiator cap 11 Pull the radiator guard downward 12 Close the engine access door i01962081 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure 126 Maintenance Section Cooling System Level Check SEBU7732 09 When a Caterpillar Extended Life Coolant is used an extender must be added to the cooling system periodically 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator guard upward Refer to Operation and Maintenance Manual Radiator Tilting EEL SAE amp Illustration 120 900956151 Note The radiator cap is located on the left side of the radiator on machines that are equipped with the 3024 engine The radiator cap is located on the right side of the radiator on machines that are equipped with the 3044 engine 3 Slowly loosen the radiator cap in order to relieve system pressure Remove the radiator cap 4 If necessary drain enough coolant from the radiator in order to allow the addition of the coolant additive 5 Add 0 17 L 0 18 qt of cooling system additive 6 Inspect the radiator cap and the gasket If the cap or the gasket is damaged replace the cap Install the radiator
42. e the retaining bolts for the bogie axle group will release the axle s retainer plate Illustration 213 901086391 1 Use a suitable lifting device to support track 4 The weight of track 4 is approximately 136 kg 300 Ib 7 Illustration 216 901083113 4 Install Tooling B 5 Lubricate the wheels and the track s drive lugs TUER with a solution of soap and water in order to Illustration 214 facilitate installation of the track 160 Maintenance Section Track Rubber Remove Replace SEBU7732 09 A IN NS TAA Illustration 217 901083132 6 Pull the handle of Tooling B away from the machine in order to push the track over the front idler wheel Note Multiple repositioning of Tooling B on the track may be required in order to completely install the track Illustration 218 7 Remove Tooling B Place the axle s retaining plate in position and install bolts 9 Tighten bolts to a torque of 50 x 10 N m 37 x 7 Ib ft g01083073 Illustration 219 g01083314 8 In order to use Tooling B for installation of the track on the rear idler wheels remove mounting plate C by removing bolt E that installs handle D to mounting plate C Then rotate mounting plate C for 180 and reinstall handle D with bolt E Tighten bolt E to a torque of 47 9 N m 35 7 Ib ft Illustration 220 901089081
43. equivalent System damage can result from freezing Illustration 244 901027404 The reservoir for the window washer solvent is located inside the cab on the left side Fill the reservoir with window washer solvent 102810705 Window Wiper Inspect Replace If Equipped SMCS Code 7305 040 7305 510 Inspect the condition of the front window wiper blade Replace the window wiper blade if the window wiper blade is worn or damaged If the window wiper blade streaks the window replace the window wiper blade 101981264 Windows Clean SMCS Code 7310 070 Use commercially available window cleaning solutions in order to clean the windows The side windows of the cab can be removed for cleaning Refer to the following procedure in order to remove the side windows 168 Maintenance Section Work Tool Lubricate SEBU7732 09 Illustration 245 g01026875 1 Release the latch 2 in order to remove the window 1 Pull downward on the window in order to remove the window Pull outward on the window in order to remove the window 2 Release the latch 4 in order to remove the window 3 Pivot the channel for the window downward Pull the window outward in order to remove the window 3 Slide the window 5 forward Pull the window outward in order to remove the window 102728710 Work Tool Lubricate SMCS Code 6700 086 Multipurpose Bucket 900534457 Illustration 246 Apply lu
44. er to catch any oil that may spill from the filter or the filter element mounting base 4 Clean the filter element mounting base Remove any part of the filter element gasket that remains on the filter element mounting base 5 Apply a light coat of oil to the gasket of the new filter element gasket 6 Install a new filter hand tight until the seal of the filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the filter use the rotation index marks as a guide 7 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter 8 Maintain the hydraulic oil level to the middle of the sight gauge Refer to Operation and Maintenance Manual Hydraulic System Oil Level Check Do not overfill the hydraulic tank 9 Inspect the gasket on the hydraulic tank filler cap for damage Replace the hydraulic tank filler cap if necessary Install the hydraulic tank filler cap 10 Close the engine access door 101957050 Hydraulic System Oil Level Check
45. evel is located on the right side of the radiator on machines that are equipped with the 3024 engine The sight gauge for the coolant level is located on the left side of the radiator on machines that are equipped with the 3044 engine 3 Maintain the coolant to the top of the sight gauge with the radiator in the LOWERED position WEILL SAE D Illustration 123 900956151 Note The radiator cap is located on the left side of the radiator on machines that are equipped with the 3024 engine The radiator cap is located on the right side of the radiator on machines that are equipped with the 3044 engine 4 If you need to add coolant to the radiator Remove the radiator cap slowly in order to relieve system pressure Note Inspect the cooling system hoses for any leaks cracks or signs of deterioration Replace any damaged hoses 5 Inspect the radiator cap and the gasket Replace the cap if the cap or the gasket is damaged Install the radiator cap 6 Tilt the radiator guard downward Illustration 124 901018341 7 The coolant reservoir is located on the left side of the engine compartment or the left side of the engine access door Maintain the coolant level in the coolant reservoir between the MIN and MAX lines 8 Close the engine access door 101958427 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 1393 010 Replace
46. g00953873 Illustration 199 2 Lubricate the wheel and the inside of the track in order to ease the installation of the track Pull the track onto the wheels Illustration 200 g00953919 3 Inspect the seal on the wheel Replace the seal if the seal is damaged Illustration 201 g01094038 4 Use the installation tool for the track in order to install the wheel onto the shaft Remove the cap g00954078 Illustration 202 5 Use a mallet in order to seat the wheel on the shaft 156 Maintenance Section Track Rubber Remove Replace SEBU7732 09 Q g00954079 Illustration 203 6 Install the washer 1 and the nut 2 Torque the nut to the following torque 168 30 N m 124 22 Ib ft g00954083 Illustration 204 7 Install the dust cap 3 and the snap ring 4 8 Tension the track Refer to Operation and Maintenance Manual Track Rubber Inspect Adjust Removing the Track 267B and 277B 1 Position the machine on firm level ground 2 Remove any work tool that is attached to the quick coupler The quick coupler is mounted to the front of the loader arms 3 Raise the loader arms and install the brace for the loader lift arm Refer to Operation and Maintenance Manual Loader Lift Arm Brace Operation 4 Detension the track Refer to Operation and Maintenance Manual Track Rubber Inspect Adjust 5 Use an app
47. he ground and this will prevent the blade from digging into the ground Note In order to properly adjust the blade the work tool coupler needs to be vertical The position of the pivot point of the blade is perpendicular to the ground Follow this procedure in order to ensure that the cutting edge will remain flat on the ground during operation Trunnion Joint Note The trunnion is a dry joint Adding grease to the trunnion simply attracts abrasive particles The tightness of the joint should be monitored Shims should be removed when the joint becomes too loose This may be indicated by excessive movement in the blade I 2 t e J ay A 9 B 3 1 A 2 4 C Illustration 106 901173519 A Trunnion Joint B Bolts C Shims e Remove the four retaining bolts B and the cap e Remove the necessary shims e Replace the cap and bolts e The tightening sequence is shown in illustration 106 Torque the bolts to 530 70 N m 391 52 Ib ft Note Some noise is typical and the noise does not indicate a problem 116 Maintenance Section Bogie and Idler Inspect Replace SEBU7732 09 102547617 Bogie and ldler Inspect Replace SMCS Code 4159 040 4159 510 4192 040 4192 510 Clean the undercarriage before inspecting the bogies and the idlers Inspect the bogies and idlers for damage and wear Note Minor damage to the rubber on the bogies and idlers is accepta
48. her Reservoir Fill 167 Window Wiper Inspect Replace 167 Windows Clean ssssseseeeeeee 167 Every 10 Service Hours or Daily Axle Bearings Lubricate sesssssse 113 Backup Alarm Test ssssssssessssss 113 Bogie and Idler Inspect Replace 116 Cooling System Level Check 126 Engine Oil Level Check suusss 131 Fuel System Primary Filter Water Separator BICI ge ETET E 135 Hydraulic System Oil Level Check 140 Lift Arm and Cylinder Linkage Lubricate 141 Quick Coupler Inspect ssssssssssss 142 Radiator Core Clean sessesess 142 Seat Belt Inspect sssseeeeeeeee 144 Sprocket Retaining Nuts Check 147 Tilt Cylinder Bearings and Bucket Linkage Bearings WUD ICAL enit emi erede 147 Track Rubber Inspect Adjust 147 Work Tool Lubricate sssseessess 168 Work Tool Mounting Bracket Inspect 170 Every 250 Service Hours Engine Oil Sample Obtain 132 Every 250 Service Hours or Monthly Belts Inspect Adjust Replace 114 Every 500 Service Hours Hydraulic Oil Sample Obtain 138
49. idle until the engine runs smoothly If the engine fails to start or if the engine continues to misfire or smoke repeat the priming procedure 4 Close the engine access door 3044 Engine Machines that are equipped with the 3044 engine are equipped with a fuel transfer pump that is electric 1 Momentarily turn the engine start switch to the START position and then return the engine start switch to the ON position Note Do not start the engine This operation only starts the fuel pump SEBU7732 09 137 Maintenance Section Fuel Tank Cap Clean 2 Leave the engine start switch in the ON position for thirty seconds 3 Attempt to start the engine If the engine starts and the engine runs rough or the engine misfires operate the engine at low idle until the engine runs smoothly If the engine fails to start or if the engine continues to misfire or smoke repeat the priming procedure 101819309 Fuel Tank Cap Clean SMCS Code 1273 070 Z2 1 Remove the fuel cap Illustration 149 g00104238 2 Inspect the cap Replace the cap if the cap is damaged 3 Wash the fuel cap in a clean nonflammable solvent and dry the fuel cap 4 Put a light coating of fuel on the cap gasket 5 Install the fuel cap 101989211 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S S N ZSA1 Up S N SLK1 7299 S N MTL1 5074 Note Drain the water and the sediment from the fuel tank when the tank is almost e
50. ing ring 2 counterclockwise Remove the bowl assembly 6 Clean the mounting base for the fuel filter water separator 7 Clean the bowl assembly for the fuel water separator 8 Install the bowl assembly onto the new fuel water separator and rotate the locking ring clockwise 9 Install the new fuel filter water separator onto the mounting base Rotate the locking ring clockwise in order to fasten the fuel filter water separator to the mounting base 10 Prime the fuel system in order to fill the fuel filter water separator with fuel Refer to Operation and Maintenance Manual Fuel System Priming Pump Operate 11 Close the engine access door 102509334 Fuel System Priming Pump Operate SMCS Code 1258 548 3024 Engine The fuel priming pump is located on top of the fuel filter water separator Illustration 148 901019689 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Push down on the top of the fuel priming pump plunger and release the fuel priming pump plunger in order to operate the fuel priming pump Operate the fuel priming pump plunger in order to fill the new filter element with fuel Continue to pump until increased resistance is felt This resistance will indicate that the filter element is full of fuel 3 Attempt to start the engine If the engine starts and the engine runs rough or the engine misfires operate the engine at low
51. ion lights 1 Open the engine access door 2 The air filter housing is located on the left side of the engine compartment on machines that are equipped with the 3024 engine The air filter housing is located on the right side of the engine compartment on machines that are equipped with the 3044 engine Illustration 129 900891467 Illustration 130 900101864 3 Unlatch the air cleaner housing cover 1 Rotate the cover and remove the cover 4 Remove the primary filter element 2 130 Maintenance Section Engine Crankcase Breather Closed Circuit Replace SEBU7732 09 Illustration 131 900038606 5 Remove the secondary filter element 6 Cover the air inlet opening Clean the inside of the air cleaner housing 7 Inspect the gasket between the air inlet pipe and the air cleaner housing Replace the gasket if the gasket is damaged 8 Uncover the air inlet opening Install a new secondary element 9 Install the primary element and the air cleaner housing cover 10 Close the engine access door 101961301 Engine Crankcase Breather Closed Circuit Replace SMCS Code 1317 510 S N ZSA1 Up S N CYC1 Up S N MDH1 Up Illustration 132 g01018922 The breather is located on the right side of the 3044 engine NOTICE Ensure that the breather pipe connections are tight Do not overfill
52. ling System Coolant Extender ELC Add 125 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 124 SEBU7732 09 113 Maintenance Section Axle Bearings Lubricate 101989568 Axle Bearings Lubricate SMCS Code 3282 086 BD S N ZSA1 Up S N SLK1 7299 S N MTL1 5074 Illustration 101 247 and 257 Illustration 102 901030370 287 Apply lubricant to the grease fittings for the rear axle bearings and the front axle bearings Repeat the process for the opposite side of the machine 101017495 Backup Alarm Test SMCS Code 7406 081 To prevent injury make sure that no people are working on the machine or near the machine To prevent injury keep the machine under control at all times 1 Get into the operator s seat Fasten the seat belt and pull the armrest downward 2 Start the engine 3 Disengage the parking brake 4 Move the speed direction control lever to the REVERSE position The backup alarm if equipped should sound immediately The backup alarm should continue to sound until the speed direction control lever is returned to the HOLD position or to the FORWARD position 100993589 Battery Recycle SMCS Code 1401 561 Always recycle a battery Never discard a battery Always return used
53. mage can result If itis necessary to replace fuses frequently an electri cal problem may exist Contact your Caterpillar dealer a P r ts d MESES d Illustration 113 901019673 The fuse panel is located behind the cover underneath the seat Remove the cover in order to access the fuse panel SEBU7732 09 123 Maintenance Section Circuit Breakers and Fuses Reset Replace 37 38 36 104 27 22 24 20 23 25 Illustration 114 Fuses and Relays Fuses 2 Finger Trigger for the Work Tool 3 Front Work Lights 4 Rear Work Lights 5 Left Tail Lamp 6 Right Tail Lamp 7 Spare 8 Backup Alarm 9 Cold Start 10 Radio 11 Spare 12 Spare 13 12 volt power socket 14 Hydraulic Quick Coupler 15 Wiper 16 Auxiliary Hydraulic ECM 17 HVAC Blower Fan and the Solenoid for the Compressor 18 Fuel Shutoff solenoid g01213939 19 Interlock ECM 20 Beacon 21 Gauges 22 The fan for the air conditioner condenser 23 Ignition Switch 24 Miscellaneous Power 25 Horn 27 Auxiliary Hydraulic C 28 Auxiliary Hydraulic C 29 Auxiliary Tools 30 Auxiliary Electrical Control C1 33 Spare 34 Auxiliary Electrical Control C2 Relays 1 Finger Trigger for the Work Tool 26 Auxiliary Hydr
54. mpty 1 Slowly remove the fuel tank cap in order to relieve the tank pressure f L EL I ELEL maman mem E EL Sea 0900 COCJ Eu ps ma J ga n nee on ee s LEE ELM o E EO EEG P c m KI SS Lf SSS Illustration 150 g00928025 location of the drain plug for the 247 and the 257 y ustration 151 900928088 location of the drain plug for the 287 2 The fuel tank drain plug for the 287 machine is located on the side of the tank Remove the access panel in the bottom of the machine in order to access the drain plug Loosen the drain plug The fuel tank drain plug for the 247 and 257 machines is located underneath the machine at the left rear corner Loosen the plug 3 Allow the water and the sediment to drain into a suitable container 4 Install the fuel tank drain plug Note Apply 5P 3413 Pipe Sealant to the threads on the drain plug 5 Install the fuel tank cap 138 Maintenance Section Hydraulic Oil Sample Obtain SEBU7732 09 101957445 Hydraulic Oil Sample Obtain SMCS Code 5050 008 7542 008 Illustration 152 g01026057 The sampling port for the hydr
55. n 175 g00955895 Note Lubricate the fittings with the loader lift arms in the fully lowered position Apply lubricant to the grease fittings 1 for the upper bearings for the tilt cylinders Apply lubricant to the grease fittings 2 for the lower bearings for the tilt cylinders Apply lubricant to the grease fittings 3 for the coupler engagement pins Apply lubricant to the grease fitting 4 for the pivot pin of the quick coupler assembly There are a total of 8 grease fittings 102303960 Track Rubber Inspect Adjust SMCS Code 4197 4198 025 4198 040 Periodic adjustment of the track tension is necessary in order to avoid damage to the tracks Maintaining the tracks at the proper tension will maximize the service life of the undercarriage components The undercarriage components include the sleeves of the drive sprocket the rings of the drive sprocket the wheels and the track Track guides are recommended for the 267B and 277B if the machine will be frequently operated on side slopes or very rough terrain 148 Maintenance Section Track Rubber Inspect Adjust SEBU7732 09 NOTICE Do not overtighten the tracks Tracks that are too tight can cause premature failure of the tracks Tracks that are too tight can cause power loss and bearing fail ures Tracks that are too loose increase the possibility of the track derailing or the drive lugs mis feeding on the drive sprocket In aggressive operating
56. n of The weight of track 4 is approximately 136 kg soap and water Use a suitable pry bar to remove 300 Ib track 4 164 SEBU7732 09 Maintenance Section Track Rubber Remove Replace Installing the Track 287B S N 2 Install the track loosely onto the undercarriage ZSA545 up poii onte track beteen the raar kw esi Table 33 Required Tools Tool Part Number Part Description Qty A 180 3033 Repair Stand Set 4 B 242 6165 Track Tool 1 Illustration 234 g01083073 3 Remove bolts 9 in order to install Tooling B Removal of bolts 9 which are the retaining bolts for the bogie axle group will release the axle s retainer plate Illustration 232 g01082508 1 Use a suitable lifting device to support track 4 The weight of track 4 is approximately 136 kg 300 Ib Illustration 235 g01083113 4 Install Tooling B 5 To facilitate installation of the track lubricate the wheels and the track s drive lugs with a solution of soap and water Illustration 233 g01083317 SEBU7732 09 165 Maintenance Section Track Rubber Remove Replace p Tab I fA BET SSS Lo dias oo g01083132 Illustration 236 6 Pull the handle of Tooling B away from the machine in order to push the track over the front idler wheel Note Multiple repositioning of Tooling B on the t
57. ns or muddy conditions the bearings should be inspected cleaned and repacked at 1000 hours with 8T1808 grease Illustration 173 901025225 typical example 1 The housing plug is a rubber plug Use a screwdriver in order to remove the plug 2 Wipe the old grease out of the housing 3 Pull out the bearing seal Replace the seal if the seal is damaged 4 Pack the bearing with clean grease and push the seal into position Place clean grease on the outside of the seal in order to protect the seal SEBU7732 09 147 Maintenance Section Sprocket Retaining Nuts Check 102125302 Sprocket Retaining Nuts Check SMCS Code 4164 535 NT Illustration 174 900953040 Check the torque on the nuts for new sprockets or for sprockets that have been reinstalled after every ten service hours until the specified torque is maintained Check the nuts on both sprockets Use a star pattern when you tighten the nuts Tighten the nuts for the 247 and 257 to the following torque 175 30 N m 129 x 22 Ib ft Tighten the nuts for the 267 277 and 287 to the following torque 270 x 40 N m 199 x 30 Ib ft Tilt Cylinder Bearings and Bucket Linkage Bearings Lubricate SMCS Code 5104 086 BD 6107 086 BD Wipe all of the grease fittings before you apply lubricant i es Illustratio
58. o move the drive frame until the second set of mounting holes are visible and the three bolts can be reinstalled Tighten the bolts Adjust the track tension Note A pry bar may be needed in order to lift the drive frame upward when you move the drive frame rearward Note Ensure that the drive lugs of the track do not contact the front axle Track Adjustment for the 287B ZSA1 544 Illustration 183 g00954633 1 Place approximately 45 kg 100 Ib between the drive sprocket and the idlers Place a straight edge across the drive sprocket and idlers Measure the track sag between the bottom of the straight edge and the top of the track The track sag should be set at 12 mm 0 5 inch If the track needs adjustment proceed with the following steps Illustration 184 901030189 2 Remove the tool that is provided for tensioning the track The tool is stored inside the engine access door Illustration 185 901011089 3 Install the track tensioner The square portion of the bracket assembly for the track tensioner fits into the square cutouts on top of the undercarriage Illustration 186 901011091 4 Loosen the jam nut and turn the adjuster in order to align the bore of the track tensioner with the holes in the mounting brackets on the drive frame 5 Install the retaining pin thr
59. on and Maintenance Manual Cooling System Water Temperature Regulator Replace for the process for replacing the thermostat 7 Add the coolant solution Refer to Operation and Maintenance Manual Capacities Refill Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations Note Premix the coolant solution before filling the cooling system The coolant solution should contain 50 percent coolant and 50 percent distilled water Note Add the coolant solution at a maximum rate of five liters per minute This will reduce the chance of trapping air inside the engine block A large amount of trapped air can cause localized heating to occur upon start up Localized heating may result in engine damage which may lead to failure of the engine 8 Start the engine Run the engine without the radiator cap until the thermostat opens and the coolant level stabilizes JEL gt D g00956179 Illustration 119 Note The sight gauge for the coolant level is located on the right side of the radiator on machines that are equipped with the 3024 engine The sight gauge for the coolant level is located on the left side of the radiator on machines that are equipped with the 3044 engine 9 Maintain the coolant level in the sight gauge 10 Stop the engine Inspect the radiator cap and the gasket Replace the cap if the cap or the gasket is damaged Install th
60. ough the holes and install the lock pin in order to secure the retaining pin SEBU7732 09 151 Maintenance Section Track Rubber Inspect Adjust 6 Keep the jam nut loosened and turn the adjuster in order to tighten the turnbuckle The track tensioner should be tight enough to hold the weight of the drive frame ey Illustration 187 g00954340 7 Remove the four retaining bolts 1 8 Turn the adjuster in order to move the drive frame rearward Turn the adjuster until the four bolts can be loosely installed into the next set of mounting holes 9 Recheck the tension per Step 1 If the sag that is measured is 12 mm 0 5 inch tighten the bolts to a torque of 215 40 N m 159 30 Ib ft If the sag that is measured is NOT 12 mm 0 5 inch repeat Step 6 through Step 6 10 Turn the adjuster slightly in order to relieve tension Note Maintain a tension that is sufficient for retaining the track tensioner in the stored position on the undercarriage 11 Tighten the jam nut to a torque of 270 40 Nm 199 x 30 Ib ft Track Adjustment for the 287B ZSA545 up Illustration 188 g01087974 1 Place approximately 45 kg 100 Ib between the drive sprocket and the idlers Place a straight edge across the drive sprocket and idle
61. ounting hardware that is 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 101970036 Seat Belt Replace SMCS Code 7327 510 Within three years of the date of installation 2 or within five years of the date of manufacture 1 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 SEBU7732 09 145 Maintenance Section Sprocket Inspect i E Illustration 170 901022746 1 Date of Manufacture 2 Date of Installation Contact your Caterpillar dealer for the
62. rack may be required in order to completely install the track 7 Remove Tooling B Place the axle s retaining plate in position and reinstall bolts 9 Tighten the bolts to a torque of 50 10 N m 39 x 7 Ib ft Illustration 237 g01083314 8 In order to use Tooling B for installation of the track on the rear idler wheels remove mounting plate C by removing bolt E that installs handle D to mounting plate C Then rotate mounting plate C for 180 and reinstall handle D with bolt E Tighten bolt E to a torque of 47 9 N m 35 x 7 Ib ft Illustration 238 901089081 9 Remove bolts 9 in order to install Tooling B Removal of bolts 9 which are the retaining bolts for the bogie axle group will release the axle s retainer plate 10 Install Tooling B 11 Lubricate the wheels and the track s drive lugs with a solution of soap and water in order to facilitate installation of the track 12 Pull the handle of Tooling B away from the machine in order to push the track over the rear idler wheels Note Multiple repositionings of Tooling B on the track may be required in order to completely install the track 13 Remove Tooling B Place the axle s retainer plate in position and reinstall bolts 9 Tighten the bolts to a torque of 50 x 10 N m 39 x 7 Ib ft 166 Maintenance Section Track Rubber Remove Replace SEBU7732 09 6 Illustration 239 g0108
63. rder to relieve hydraulic pressure Move the engine start Switch key to the OFF position ULLA i WORE EU EERE SIR ENEBERBBEBERBER n Illustration 154 900926534 1 Remove the hydraulic tank filler cap SEBU7732 09 139 Maintenance Section Hydraulic System Oil Filter Replace Illustration 155 g01021146 2 Remove the access panel in the belly guard underneath the machine Illustration 156 901030411 3 Remove the plug from the end of the drain hose Pull the drain hose through the access panel in the belly guard Open the drain valve and drain the oil into a suitable container 4 Close the drain valve and pull the drain hose back into the machine Install the drain plug into the drain hose 5 Change the hydraulic system filter Refer to Operation and Maintenance Manual Hydraulic System Oil Filter Change 6 Fill the hydraulic system oil tank Refer to Operation and Maintenance Manual Lubricant Viscosities and Operation and Maintenance Manual Capacities Refill 7 Maintain the hydraulic oil level approximately in the middle of the sight gauge Check the oil level with the loader arms in the fully lowered position Note The oil must be free of bubbles If bubbles are present in the oil air is entering the hydrauli
64. replacement of the seat belt 102110179 Sprocket Inspect SMCS Code 4164 040 Note Operating the machine in conditions that are extremely muddy or sandy will cause accelerated wear on the drive sprocket and other undercarriage components It is important to clean the undercarriage of the machine daily in order to maximize component life In order to service the drive sprocket the tracks must be removed Refer to Operation and Maintenance Manual Track Rubber Remove Install Sleeves Illustration 171 900801623 The drive sprocket is equipped with two types of sleeves The inner sleeves 2 are held in position by the rings of the sprocket 4 and 5 The outer sleeves 3 are free to rotate on the inner sleeves Measure thickness A for the outer sleeves If the thickness of the outer sleeves measures less than the minimum thickness that is listed in the following table replace the sleeves Note When you replace the outer sleeves rotate the inner sleeves for 180 If the inner sleeves have already been rotated replace the inner sleeves Table 27 247 257 267 277 and 287 Minimum Thickness 3 mm 0 12 inch Component Outer Sleeve Rings The inner rings 5 and the outer rings 4 of the drive sprocket will wear from the rotation of the outer sleeves Measure the thickness B of the inner rings and outer rings If the thickness of the inner ring or outer ring me
65. ropriate floor jack to lift the machine so that the track is nearly off of the ground Use appropriate jack stands in order to block up the machine Illustration 205 900954089 6 Remove the three bolts 1 2 and 3 that secure the drive frame Note The bolt 2 is located on the opposite side of the drive frame from bolt 3 It will be necessary to raise the body of the machine in order to gain access to this bolt Note When you reinstall the three bolts tighten bolts 2 and 3 to the following torque 120 20 N m 89 15 Ib ft When you reinstall the bolt 1 tighten the bolt to the following torque 430 60 N m 317 x 44 Ib ft 7 Install the track adjusting tool into the brackets A Ratchet the tool in order to slide the drive frame forward Note When you reinstall the track you must slide the drive frame rearward into the original position A pry bar may be needed in order to pry the drive frame upward when you slide the drive frame rearward SEBU7732 09 157 Maintenance Section Track Rubber Remove Replace Illustration 206 g00954090 8 Remove the two bolts and the locknuts 7 Remove the four bolts and lockwashers 5 Remove the support plate for the drive sprocket 6 Note When you reinstall the bolts 6 tighten the bolts to the following torque 120 20 N m 89 15 Ib ft When you reinstall the bolts 7 tighten the bolts to the following torque 105 20 N m 77 x 15
66. rs Measure the track sag between the bottom of the straight edge and the top of the track The track sag should be set at 12 mm 0 5 inch If the track needs adjustment proceed with the following steps Illustration 189 901081668 2 Locate the track tensioner on the undercarriage frame Illustration 190 901081665 152 Maintenance Section Track Rubber Inspect Adjust SEBU7732 09 3 Remove the two retaining bolts 1 in the front of the drive assembly Illustration 191 901081661 4 Loosen the jam nut and turn the adjuster in order to move the drive assembly in the required direction 5 Keep the jam nut loosened The track tensioner should be tight enough to hold the weight of the drive frame 6 Recheck the tension per Step 1 If the sag that is measured is 12 mm 0 5 inch reinstall the two retaining bolts into the undercarriage Tighten the bolts to a torque of 240 40 N m 177 x 30 Ib ft If the sag that is measured is NOT 12 mm 0 5 inch repeat Step 4 through Step 6 7 Tighten the jam nut to a torque of 270 40 N m 199 x 30 Ib ft Additional Adjustment for the 287 In certain situations the tracks are in usable condition but the normal adjustment procedure will not tension the track to the recommended specification By reversing the position of the 238 7709 Bracket additional track tension can be achieved This is possible because the slot for the brackets is offset
67. sed air high pressure water or steam to remove dust and other debris from the radiator fins However the use of compressed air is preferred SEBU7732 09 143 Maintenance Section Refrigerant Dryer Replace 3 Clean the radiator core NOTICE Do not clean a running fan with high pressure water Fan blade failure can result 4 Remove any dirt or debris from the fan the fan hub the oil cooler the radiator guard and the fan guard Note Dirt or debris on the cooling fan can cause an imbalance 5 Tilt the radiator guard downward 6 Close the engine access door 101968724 Refrigerant Dryer Replace If Equipped SMCS Code 7322 510 Personal injury can result from contact with refrig erant Contact with refrigerant can cause frost bite Keep face and hands away to help prevent injury Protective goggles must always be worn when re frigerant lines are opened even if the gauges in dicate the system is empty of refrigerant Always use precaution when a fitting is removed Slowly loosen the fitting If the system is still un der pressure release it slowly in a well ventilated area Personal injury or death can result from inhaling refrigerant through a lit cigarette Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Do not smoke when
68. servicing the track The machine must be on a hard level surface be fore the track is removed or personal injury or death could occur 1 Park the machine on a hard level surface Personal injury or death can result from improper lifting or blocking When a jack is used to lift the machine stand clear of the area Use a jack that is rated for the cor rect capacity to lift the machine Install blocks or stands before performing any work on the ma chine 2 Remove the track Refer to Operation and Maintenance Manual Track Rubber Remove Replace for the correct procedure Illustration 110 g00873251 3 Clean the area around the filler plug for the tube for the bogie or the idler Remove the filler plug 4 Rotate the tube so that the filler plug hole is approximately level with the ground The oil level should show at the bottom of the filler plug hole Note The oil level will be low if the seals in the tube are leaking If the oil level is low replace the oil seals in the tube and refill the tube See Operation and Maintenance Manual Capacities Refill 5 Apply 5P 3413 Pipe Sealant to the threads of the filler plug Install the filler plug 6 Repeat the procedure on each tube for the bogie and the idler i01743875 Bucket Cutting Edges Inspect Replace SMCS Code 6801 040 6801 510 Personal injury or death can result from bucket falling Block the bucket before changing
69. servicing air conditioners or wherever refrigerant gas may be present Use a certified recovery and recycling cart to prop erly remove the refrigerant from the air condition ing system NOTICE If the refrigerant system has been open to the outside air without being plugged for more than 30 minutes the receiver dryer must be replaced Moisture will en ter an open refrigerant system and cause corrosion which will lead to component failure Refer to Service Manual SENR5664 Air Conditioning and Heating R 134a For All Caterpillar Machines for the proper procedure to change the receiver dryer assembly and for the procedure to reclaim the refrigerant gas Note The receiver dryer must also be replaced when the air conditioning system is evacuated 102798931 Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS Inspect SMCS Code 7323 040 7325 040 T Illustration 167 g01022156 1 Front ROPS retaining bolt one bolt per side 144 Maintenance Section Seat Belt Inspect SEBU7732 09 2 3 oo 00 OIL AANA MAANA OOS aaa VOODOO at d ii NANMANWA BEBNENENENNNENBERER MERMNNENNENNERBER MENERERER UOO OL Illustration 168 g00925477 2 Rear ROPS retaining bolt one bolt per side 3 Retaining bolts for the
70. tall the oil filler plug 9 Start the engine and allow the oil to warm Check for leaks CANAAAAA 0 Illustration 143 900849728 10 Stop the engine and allow the oil to drain back into the oil pan Fill the crankcase to the FULL mark on the dipstick 1 Do not exceed the FULL mark on the dipstick Add oil or drain oil if it is necessary 11 Tilt the radiator downward 12 Close the engine access door 101020861 Engine Valve Lash Check SMCS Code 1105 025 Refer to the Service Manual for the complete adjustment procedure for the engine valve lash A qualified mechanic should adjust the engine valve lash and the fuel injector timing because special tools and training are required 100916186 Fuel Injection Timing Check SMCS Code 1251 531 Note The correct fuel timing specification is found on the Engine Information Plate Fuel timing specifications may vary for different engine applications and or for different power ratings A qualified mechanic should adjust the fuel injection timing because special tools and training are required Refer to the Service Manual for the complete adjustment procedure for the fuel injection timing Refer to your Caterpillar dealer for the complete adjustment procedure for the fuel injection timing SEBU7732 09 135 Maintenance Section Fuel System Primary Filter Water Separator Drain 102645127 Fuel System Primary Filter Water Separator Drain
71. the engine cranckcase If there is too much oil in the crankcase oil may enter the breather Oil entering the breather may cause the engine speed to increase rapidly without control 1 Firmly grasp the breather and pull up on the breather in order to remove the breather 2 Remove the breather hoses Clean the hoses with nonflammable solvent 3 Install a new breather Ensure that the breather is properly seated in the base 4 Install the breather hoses Ensure that the connections are tight SEBU7732 09 131 Maintenance Section Engine Crankcase Breather Clean 102022498 Engine Crankcase Breather Clean SMCS Code 1317 070 S N SLK1 7299 S N MTL1 5074 Note Ensure that the area around the vent hole on the breather cover is clean and that the vent hole is not restricted Ensure that the components of the breather assembly are seated in the correct positions Otherwise engine damage could result 1 Open the engine access door Refer to Operation and Maintenance Manual Access Doors and Covers 2 Tilt the radiator upward Refer to Operation and Maintenance Manual Radiator Tilting Illustration 133 901018945 Illustration 134 g01044243 3 The breather is located on top of the valve cover on the 3024 engine Remove the screws 1 Remove the breather cover 2 4 Remove the diaphragm assembly 4 Remove the spring 3 The diaphragm assembly consists of the
72. two bolts in the next available holes Reinstall the two bolts lockwashers and locknuts Tighten the two bolts to the following torque 120 N m 89 Ib ft Remove the tool Note In order to detension the track for removal pivot the idlers backward Note If the idler is already in a vertical position it may be necessary to relocate the mounting bolts for the drive frame into the second set of holes that is provided in order to achieve the proper track tension Refer to Operation and Maintenance Manual Adjustment of the Drive Frame for the 267 and 277 for the correct procedure 5 Recheck the tension of the track Adjustment of the Drive Frame for the 267B and 277B 900900564 Illustration 182 1 Fully lower the wheels that tension the track so that all tension is removed from the track Remove the bolts 1 2 and 3 that secure the drive frame Note The bolt 2 is located on the opposite side of the drive frame from bolt 3 It will be necessary to raise the body of the machine in order to gain access to this bolt 150 Maintenance Section Track Rubber Inspect Adjust SEBU7732 09 2 Install the tool into the brackets A Position the tool so that the fixed end of the tool is positioned inside the hooks Slide the pin that is located on the other end of the tool through the holes in the undercarriage in order to secure the tool Ratchet the tool in order to move the drive frame backward Continue t

MAINTENANCE INTERVALS - Safety

Contents

Download Pdf Manuals

Related Search

Related Contents