MAINTENANCE INTERVALS

Operation and Maintenance Manual Excerpt

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KEBU7534-03 February 2008

Operation and Maintenance Manual

PS-150C Paving Compactor
FPS1-Up (Machine)

SAFETY.CAT.COM

58 Maintenance Section Maintenance Interval Schedule

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Every 50 Service Hours or Weekly

Air Compressor Air Filter - Clean/Inspect ............. Air Compressor Oil - Check .................................. Tire Ination - Check ............................................. Wheel Bearings (Front) - Lubricate ....................... 60 61 88 91

Maintenance Interval Schedule

SMCS Code: 1000; 7000 Ensure that all safety information, warnings and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, uids, lters, and the replacement of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components. Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, in order to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance. Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed.

Every 50 Service Hours or Monthly

Fuel Tank Water and Sediment - Drain ................. 79

Every 100 Service Hours or 2 Weeks

Water Tank Strainer - Clean and Inspect .............. 91

Initial 250 Service Hours

Strainer (Flushing System) - Clean ....................... 87

Every 250 Service Hours

Toggle Switch - Inspect ......................................... 89

Every 250 Service Hours or Monthly

Air Compressor Oil - Change ................................ Belts - Inspect/Adjust/Replace .............................. Oscillating and Steering Bar - Lubricate ............... Steering Cylinder Ends - Lubricate ....................... 60 63 85 87

When Required
Ballast - Remove/Install ........................................ Battery - Recycle .................................................. Battery or Battery Cable - Inspect/Replace .......... Circuit Breakers - Reset ........................................ Engine Air Filter Primary Element - Clean/ Replace ............................................................... Engine Air Filter Secondary Element - Replace ... Engine Compartment - Clean ............................... Fuel System - Prime ............................................. Fuses - Replace .................................................... Oil Filter - Inspect .................................................. Radiator and Hydraulic Oil Cooler - Clean ............ Tire Mat - Replace ................................................ Tire Scraper - Inspect/Adjust/Replace .................. Water Spray Nozzles - Clean ................................ Water Spray System - Drain ................................. Water Spray System Filter - Clean ....................... Wheel Nuts - Tighten ............................................ 62 63 63 65 72 74 75 78 79 84 85 88 88 89 90 90 92

Every 250 Service Hours or 3 Months

Engine Oil Sample - Obtain .................................. 76

Initial 500 Hours (for New Systems, Relled Systems, and Converted Systems)
Cooling System Coolant Sample (Level 2) Obtain ................................................................. 68

Every 500 Service Hours

Cooling System Coolant Sample (Level 1) Obtain ................................................................. 68 Strainer (Flushing System) - Clean ....................... 87

Every 500 Service Hours or 6 Months

Air Compressor Air Filter - Replace ...................... Braking System - Test ........................................... Drive Shaft - Lubricate .......................................... Engine Oil and Filter - Change ............................. Fuel System Water Separator Element - Replace .. Hydraulic System Oil Sample - Obtain ................. 60 64 71 76 78 82

Every 10 Service Hours or Daily

Air Tank Moisture and Sediment - Drain ............... Backup Alarm - Test .............................................. Cooling System Coolant Level - Check ................ Engine Air Filter Service Indicator - Inspect .......... Engine Oil Level - Check ...................................... Fuel System Water Separator - Drain ................... Hydraulic System Oil Level - Check ..................... Indicators and Gauges - Test ................................ Neutral Start Switch - Test .................................... Seat Belt - Inspect ................................................ 61 61 69 75 75 78 82 83 84 86

Every 1000 Service Hours or 1 Year

Battery - Clean/Check ........................................... Cooling System Pressure Cap - Clean/Replace ... Engine Valve Lash - Check ................................... Fuel Tank Cap Filter and Strainer Replace/Clean .................................................... Hydraulic System Oil Filter - Replace ................... 62 69 77 78 81

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59 Maintenance Section Maintenance Interval Schedule

Hydraulic System Tank Vent - Replace ................. 83 Hydraulic Tank Strainer - Clean ............................ 83 Rollover Protective Structure (ROPS) - Inspect .... 86

Every 2000 Service Hours or 1 Year

Crankshaft Vibration Damper - Inspect ................. 71 Hydraulic System Oil - Change ............................. 80

Every Year
Cooling System Coolant Sample (Level 2) Obtain ................................................................. 68

Every 3000 Service Hours or 2 Years

Cooling System Water Temperature Regulator Replace ............................................................... 70 Engine Water Pump - Inspect ............................... 77

Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................... 86

Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .... 67

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 65

60 Maintenance Section Air Compressor Air Filter - Clean/Inspect

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Air Compressor Air Filter Clean/Inspect

SMCS Code: 1803-571-FI

Air Compressor Air Filter Replace

SMCS Code: 1803-510-FI

Illustration 51

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Illustration 52

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1. Remove the cover for the air lter housing. 2. Clean the inside of the air lter housing. 3. Clean the air lter element. Note: Use pressurized air in order to clean the air lter element. 4. Inspect the air lter element for tears and/or holes. Discard the air lter element if the air lter element is damaged. 5. Install the air lter element. 6. Install the cover for the air lter housing.

1. Remove the cover from the air intake housing. 2. Remove the air lter element. 3. Install a new air lter element. 4. Install the cover for the air intake housing.
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Air Compressor Oil - Change

SMCS Code: 1803-044-OC; 1803-510-OC

Illustration 53

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1. Place a suitable container under the drain plug. Remove the drain plug. Refer to the Operation and Maintenance Manual, General Hazard Information for information that pertains to containing uid spillage. 2. Allow the oil to completely drain.

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61 Maintenance Section Air Compressor Oil - Check

3. Clean the drain plug. Install the drain plug. Note: Dispose of the used oil according to local regulations. 4. Fill the crankcase for the air compressor to the correct uid level.
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Backup Alarm - Test

SMCS Code: 7406-081

Air Compressor Oil - Check

SMCS Code: 1803-535-FLV

Illustration 56 Illustration 54
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The backup alarm is located at the rear of the machine. 1. Turn the battery disconnect switch clockwise in order to turn the electrical system ON. 2. Turn the engine start switch to the ON position in order to perform the test.

Maintain the oil level between the two level marks on the dipstick. Do not ll above the second mark on the dipstick.
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Air Tank Moisture and Sediment - Drain

SMCS Code: 5505-543

Illustration 57

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3. Apply the parking brake (1). Move the propel control lever (2) to the REVERSE position.
Illustration 55
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Open the valve in order to drain the moisture from the air tank.

Note: The backup alarm should start to sound immediately. 4. The backup alarm will continue to sound until the propel control lever is moved to the NEUTRAL position or to the FORWARD position.

62 Maintenance Section Ballast - Remove/Install

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Ballast - Remove/Install
SMCS Code: 7056-011; 7056-012

4. Use a shovel or use a water hose in order to clean the solid ballast through the outlet opening of the ballast compartment. 5. Install the outlet cover. 6. Install the solid or liquid ballast in the ballast compartments in order to maintain proper balance of the machine. 7. Install the platform covers.
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Battery - Clean/Check
SMCS Code: 1401-535
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Illustration 58 Drain for liquid ballast

1. Remove the drain plug in order to drain the liquid ballast. After draining, install the drain plug.

Personal injury may occur from failure to properly service the batteries. Batteries give off ammable fumes that can explode. Electrolyte is an acid and can cause personal injury if it contacts the skin or eyes. Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jumper cable ends to contact each other or the engine. Improper jumper cable connections can cause an explosion. Always wear protective glasses when working with batteries. 1. Open the engine compartment.

Illustration 59

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2. Remove the outlet cover on the right side of the machine in order to remove a solid ballast.

Illustration 61 Right side of machine

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Illustration 60

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3. Remove the four platform covers.

Note: The batteries that are supplied with the machines are maintenance free batteries. You do not need to check the level of the electrolyte in the maintenance free batteries.

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63 Maintenance Section Battery - Recycle

2. Tighten the battery retainers on the battery at every 1000 hours. 3. Check the following items at every 1000 hours. If necessary, check the following items more often. a. Clean the top of the batteries with a clean cloth. b. Clean the battery terminals. As needed, coat the battery terminals with petroleum jelly. 4. Close the engine compartment.
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2. Turn the battery disconnect switch to the OFF position. Remove the key. 3. Disconnect the negative battery cable at the battery. 4. Disconnect the positive battery cable at the battery. 5. Disconnect the battery cables at the battery disconnect switch. The battery disconnect switch is connected to the machine frame. 6. Make necessary repairs or replace the battery. 7. Connect the battery cable at the battery disconnect switch. 8. Connect the positive battery cable of the battery. 9. Connect the negative battery cable of the battery. 10. Install the key and turn the battery disconnect switch to the ON position.
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Battery - Recycle
SMCS Code: 1401-561 Always recycle a battery. Never discard a battery. Always return used batteries to one of the following locations:

A battery supplier An authorized battery collection facility Recycling facility

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Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510 Your engine can be equipped with a fan drive belt and with accessory drive belts. Your engine can also be equipped with an alternator belt. For maximum engine performance and maximum utilization of your engine, inspect the belts for wear and for cracking. Check the belt tension. Adjust the belt tension in order to minimize belt slippage. Belt slippage will decrease the belt life. Belt slippage will also cause poor performance of the alternator and of any driven equipment. If new belts are installed, recheck the belt adjustment after 30 minutes of operation. If two belts or more are required for an application, replace the belts in belt sets. If only one belt of a matched set is replaced, the new belt will carry more load. This is due to the fact that the older belts are stretched. The additional load on the new belt could cause the new belt to break.

Battery or Battery Cable Inspect/Replace

SMCS Code: 1401-040; 1401-510; 1402-040; 1402-510

Personal injury can result from battery fumes or explosion. Batteries give off ammable fumes that can explode. Electrolyte is an acid and can cause personal injury if it contacts the skin or eyes. Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jumper cable ends to contact each other or the engine. Improper jumper cable connections can cause an explosion. Always wear protective glasses when working with batteries. 1. Turn the engine start switch key to the OFF position. Turn all of the switches to the OFF position.

Alternator Belt
1. Stop the engine. 2. Open the engine compartment.

64 Maintenance Section Braking System - Test

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Fasten the seat belt before checking the parking brake. The following tests are used to determine if the parking brake is functional on a specied grade or a specied slope. These tests are not intended to measure the maximum brake holding effort. Read all of the steps before you perform the following procedure.

Illustration 62

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3. To check the belt tension, apply 110 N (25 lb) of force midway between the pulleys. Correctly adjusted belts will deect 14 to 20 mm (1/2 to 3/4 inch). 4. In order to adjust the alternator belt, loosen the alternator adjusting bracket bolt and the mounting bracket bolt. 5. To achieve the correct belt tension, move the alternator inward or move the alternator outward, as required. 6. If necessary, use a pry bar to bear against the alternator bracket. 7. Tighten the mounting bracket bolt and the alternator adjusting bracket bolt. 8. If new belts are installed, check the belt adjustment again after 30 minutes of engine operation at the rated speed. 9. Check the position of the fan shroud. Adjust the position of the fan shroud so that the fan will not rub against the shroud. Maintain a 9.4 mm (0.38 inch) clearance between the fan and the shroud.
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Illustration 63

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Position the machine on the incline of the slope, but near the base of the slope in order to check the parking brake. The test position should be 26 percent or a 15 degree slope. 1. Start the engine. Refer to the Operation and Maintenance Manual, Engine Starting for information on starting the engine. 2. Move the machine into the test position. 3. Place the throttle control into the LOW IDLE position. 4. Engage the parking brake. The machine should not move under the following conditions.

The engine is at low idle.

Braking System - Test

SMCS Code: 4250-081; 4251-081; 4267-081

The parking brake is applied. The machine is positioned on the specied

slope.

Parking Brake Holding Ability Test

Note: If the machine conguration changes, the parking brakes need to be tested. Check the area around the machine. Make sure that the machine is clear of personnel and clear of obstacles.

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65 Maintenance Section Circuit Breakers - Reset

Personal injury can result if the machine moves while testing. If the machine begins to move, place the throttle control in HIGH IDLE, release the parking brake and use the propel lever in order to move the machine to a level surface. 5. Park the machine on a level surface. 6. Stop the engine. NOTICE If the machine moved during the brake test, consult your Caterpillar dealer. The dealer must inspect the brake system and make any necessary repairs before the machine is returned to operation.

Circuit Breaker/Reset Push in the button in order to reset the circuit breaker. If the electrical system is functioning properly, the button will remain depressed. If the button does not remain depressed, check the appropriate electrical circuit. Repair the electrical circuit, if necessary. Breaker for the Glow Plugs (1)

Main Breaker (2)

Breaker for the Alternator (3)

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Circuit Breakers - Reset

SMCS Code: 1420-529 The circuit breaker panel is located in the engine compartment.

Cooling System Coolant (ELC) - Change

SMCS Code: 1395-044-NL Drain the coolant whenever the coolant is dirty. Drain the coolant when foam is observed. 1. Stop the engine. Allow the cooling system to cool completely. 2. Open the hood for the engine.

Illustration 64

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Illustration 65

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66 Maintenance Section Cooling System Coolant (ELC) - Change

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5. Drain valve (2) is located on the bottom corner of the radiator. Open drain valve (2). Allow the coolant to drain into a suitable container. 6. Close drain valve (2). Fill the radiator with a solution which consists of clean water and of cooling system cleaner. Once the radiator is lled, ll the cooling system expansion tank to the full line. The concentration of the cooling system cleaner in the solution should be between 6 percent and 10 percent. 7. Install radiator cap (1) and the cap for the expansion tank (3).
Illustration 66
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8. Close the hood for the engine. 9. Start the engine. Run the engine for 90 minutes. Stop the engine. Allow the cooling system to cool completely. 10. Slowly loosen radiator cap (1) and remove radiator cap (1). 11. Remove the cap for expansion tank (3). 12. Drain the cleaning solution into a suitable container. 13. While the engine is stopped, ush the system with water. Flush the system until the draining water is transparent. 14. Close drain valve (2). NOTICE Mixing Extended Life Coolant (ELC) with other products reduces the effectiveness of the coolant and shortens coolant life. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specications for premixed or concentrate coolants. Use only Caterpillar Extender with Caterpillar ELC. Failure to follow these recommendations could result in the damage to cooling systems components. If ELC cooling system contamination occurs, refer to Operation and Maintenance, Extended Life Coolant (ELC) under the topic ELC Cooling System Contamination. 15. Add the coolant solution. See the following topics:

Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes. 3. Slowly loosen radiator cap (1) and remove radiator cap (1). 4. Remove the cap for expansion tank (3). NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.

Special Publication, SEBU6250, Caterpillar

Machine Fluids Recommendations, Cooling System Specications (Rell)

Operation and Maintenance Manual, Capacities

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67 Maintenance Section Cooling System Coolant Extender (ELC) - Add

Note: If you are using Caterpillar antifreeze, do not add the supplemental coolant additive at this time. 16. Start the engine. Run the engine without the radiator cap until the thermostat opens and the coolant level stabilizes. 17. Completely ll the radiator. Note: The radiator must remain completely full in order for the expansion tank to work properly. 18. Replace radiator cap (1) if the gasket is damaged. Install radiator cap (1). 19. Maintain the level of the coolant to the full line on expansion tank (4). 20. Install the cap for expansion tank (3). 21. Stop the engine. 22. Close the hood for the engine.
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NOTICE Topping off or mixing Cat ELC with other products that do not meet Caterpillar EC-1 specications reduces the effectiveness of the coolant and shortens coolant service life. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specication for pre-mixed or concentrate coolants. Use only Extender with Cat ELC. Failure to follow these recommendations can result in shortened cooling system component life. 1. Stop the engine. Allow the cooling system to completely cool. 2. Open the engine compartment.

Cooling System Coolant Extender (ELC) - Add

SMCS Code: 1352-544-NL

At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the ll cap is cool enough to touch with your bare hand. Remove the ll cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury. When a Caterpillar Extended Life Coolant (ELC) is used, an Extender must be added to the cooling system. Use a 8T-5296 Coolant Test Kit to check the concentration of the coolant. Refer to the Special Publication, SEBU6250, Caterpillar Machines Fluids Recommendations, Cooling System Specications for more information about the addition of Extender.

Illustration 67

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3. Remove the cap for the expansion tank. 4. Add the recommended amount of extender to the coolant system. Refer to the Special Publication, SEBU6250, Caterpillar Machines Fluids Recommendations, Cooling System Specications for the proper amount. 5. Maintain the level of the coolant to the full line on the cooling system expansion tank. Note: The radiator must remain completely full in order for the expansion tank to work properly. 6. Install the cap for the expansion tank. 7. Close the engine compartment.

68 Maintenance Section Cooling System Coolant Sample (Level 1) - Obtain

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Place the sample in the mailing tube immediately

after obtaining the sample in order to avoid contamination.

Cooling System Coolant Sample (Level 1) - Obtain

SMCS Code: 1395-008 NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. Note: Level 1 results may indicate a need for Level 2 Analysis.

Never collect samples from expansion bottles. Never collect samples from the drain for a system.
Submit the sample for Level 1 analysis. For additional information about coolant analysis, see Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer.
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Cooling System Coolant Sample (Level 2) - Obtain

SMCS Code: 1350-008; 1395-008 NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers.

Illustration 68

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Obtain the sample of the coolant as close as possible to the recommended sampling interval. In order to receive the full effect of SOS analysis, you must establish a consistent trend of data. In order to establish a pertinent history of data, perform consistent samplings that are evenly spaced. Supplies for collecting samples can be obtained from your Caterpillar dealer. Use the following guidelines for proper sampling of the coolant:

Illustration 69

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Complete the information on the label for the

sampling bottle before you begin to take the samples. bags.

Keep the unused sampling bottles stored in plastic Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples from any other location. are ready to collect the sample.

Obtain the sample of the coolant as close as possible to the recommended sampling interval. Supplies for collecting samples can be obtained from your Caterpillar dealer. Refer to Operation and Maintenance Manual, Cooling System Coolant Sample (Level 1) - Obtain for the guidelines for proper sampling of the coolant. Submit the sample for Level 2 analysis.

Keep the lids on empty sampling bottles until you

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69 Maintenance Section Cooling System Coolant Level - Check

For additional information about coolant analysis, see Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer.
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Cooling System Pressure Cap - Clean/Replace

SMCS Code: 1382-070; 1382-510 1. Open the engine compartment.

Cooling System Coolant Level - Check

SMCS Code: 1350-535-FLV

At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the ll cap is cool enough to touch with your bare hand.
Illustration 71

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Remove the ll cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury. 1. Open the engine compartment.

2. The cooling system pressure cap is on the top of the radiator.

Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns.

Illustration 70

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2. Maintain the level of the coolant in the expansion tank to the level line. 3. Close the engine compartment.

Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes. 3. Remove the cooling system pressure cap slowly in order to relieve pressure. 4. Inspect the cooling system pressure cap for foreign material, for deposits, and for damage. Clean the cooling system pressure cap with a clean cloth. If the cooling system pressure cap is damaged, replace the cooling system pressure cap.

70 Maintenance Section Cooling System Water Temperature Regulator - Replace

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5. Install the cooling system pressure cap. 6. Close the engine compartment.
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At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the ll cap is cool enough to touch with your bare hand. Remove the ll cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury. 2. Remove radiator cap (1) in order to relieve the pressure in the cooling system. 3. Loosen hose clamp (2) and remove hose (3) from water temperature regulator housing (4). 4. Remove bolts (5) from water temperature regulator housing (4) and remove water temperature regulator housing (4). 5. Remove the gasket and remove the water temperature regulator from the water temperature regulator housing. Make a note of the orientation of the old regulator. NOTICE The water temperature regulators may be reused if the water temperature regulators are within test specications, are not damaged, and do not have excessive buildup of deposits. NOTICE Since Caterpillar engines incorporate a shunt design cooling system, it is mandatory to always operate the engine with a water temperature regulator. Depending on load, failure to operate with a water temperature regulator could result in either an overheating or an overcooling condition. NOTICE If the water temperature regulator is installed incorrectly, it will cause the engine to overheat. 6. Install a new water temperature regulator. Orient the regulator in the same manner as the old regulator. Install a new gasket. Install the water temperature regulator housing.

Cooling System Water Temperature Regulator Replace

SMCS Code: 1355-510; 1393-010 Replace the water temperature regulator on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system. The water temperature regulator should be replaced after the cooling system has been cleaned. Replace the water temperature regulator while the cooling system is completely drained. Replace the water temperature regulator while the cooling system coolant is drained to a level below the water temperature regulator housing. NOTICE Failure to replace the engines water temperature regulator on a regularly scheduled basis could cause severe engine damage. Note: If you are only replacing the water temperature regulator, drain the cooling system coolant to a level that is below the water temperature regulator housing. 1. Open the engine compartment.

Illustration 72

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7. Install the water temperature regulator housing and the hose. Tighten the hose clamp.

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71 Maintenance Section Crankshaft Vibration Damper - Inspect

Illustration 73

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Illustration 75

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8. Add the cooling system coolant. Maintain the level of the coolant to the full line on the cooling system expansion tank. Note: The radiator must be completely full in order for the expansion tank to work properly. 9. Inspect cooling system pressure cap and the gasket for damage. Replace the pressure cap if the pressure cap or the gasket are damaged. 10. Install the cooling system pressure cap. 11. Close the engine compartment.
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Damage to the crankshaft vibration damper or failure of the crankshaft vibration damper can increase torsional vibrations. This can result in damage to the crankshaft and to other engine components. A deteriorating damper can cause excessive gear train noise at variable points in the speed range. The damper is mounted to the crankshaft on the front of the engine. Visually inspect the crankshaft vibration damper for damage. Check the bolts for proper tightness. Refer to Specication, SENR3130, Torque Specications. Close the engine compartment.
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Crankshaft Vibration Damper - Inspect

SMCS Code: 1205-040 Open the engine compartment.

Drive Shaft - Lubricate

SMCS Code: 3253-086

Accidental machine starting can cause injury or death to personnel working on the machine. To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps. Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on. 1. Shut off the engine. 2. Open the engine compartment.

Illustration 74

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72 Maintenance Section Engine Air Filter Primary Element - Clean/Replace

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3. Turn the battery disconnect switch to the OFF position. 4. Wipe all ttings, caps, and plugs on the two drive shafts before servicing.

Illustration 77

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1. Remove cover (1) for the air lter housing.

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Illustration 76 Right drive shaft

2. Remove primary lter element (2) from the air lter housing. 3. Clean the inside of the air lter housing. 4. If the machine is equipped with a vacuator valve, clean the vacuator valve on the cover for the air lter housing. 5. Install a clean primary air lter element. Install the cover for the air lter housing.

5. Lubricate the hydraulic tting on each drive shaft. 6. Turn the battery disconnect switch to the ON position. 7. Close the engine compartment.
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Note: Refer to Cleaning Primary Air Filter Elements. 6. Reset the engine air lter service indicator. 7. Close the access door. If the yellow piston in the indicator moves into the red zone after starting the engine or the exhaust smoke is still black after installation of a clean primary lter element, install a new primary lter element. If the piston remains in the red zone replace the secondary element.

Engine Air Filter Primary Element - Clean/Replace

SMCS Code: 1054-070-PY; 1054-510-PY NOTICE Service the air cleaner only with the engine stopped. Engine damage could result. Service the air cleaner lter element when the yellow piston on the engine air lter service indicator enters the red zone or the indicator reads 63.5 cm (25 inch) of water. Refer to Operation and Maintenance Manual, Engine Air Filter Service Indicator - Inspect.

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73 Maintenance Section Engine Air Filter Primary Element - Clean/Replace

Cleaning Primary Air Filter Elements

NOTICE Caterpillar recommends certied air lter cleaning services available at participating Caterpillar dealers. The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufcient lter life. Observe the following guidelines if you attempt to clean the lter element: Do not tap or strike the lter element in order to remove dust. Do not wash the lter element. Use low pressure compressed air in order to remove the dust from the lter element. Air pressure must not exceed 207 kPa (30 psi). Direct the air ow up the pleats and down the pleats from the inside of the lter element. Take extreme care in order to avoid damage to the pleats. Do not use air lters with damaged pleats, gaskets, or seals. Dirt entering the engine will cause damage to engine components. The primary air lter element can be used up to six times if the element is properly cleaned and if the element is properly inspected. When the primary air lter element is cleaned, check for rips or tears in the lter material. The primary air lter element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings. NOTICE Do not clean the air lter elements by bumping or tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets, or seals. Damaged elements will allow dirt to pass through. Engine damage could result. Visually inspect the primary air lter elements before cleaning. Inspect the air lter elements for damage to the seal, the gaskets, and the outer cover. Discard any damaged air lter elements. There are two common methods that are used to clean primary air lter elements:

Pressurized Air
Pressurized air can be used to clean primary air lter elements that have not been cleaned more than two times. Pressurized air will not remove deposits of carbon and oil. Use ltered, dry air with a maximum pressure of 207 kPa (30 psi).

Illustration 78

g00281692

Note: When the primary air lter elements are cleaned, always begin with the clean side (inside) in order to force dirt particles toward the dirty side (outside). Aim the hose so that the air ows inside the element along the length of the lter in order to help prevent damage to the paper pleats. Do not aim the stream of air directly at the primary air lter element. Dirt could be forced further into the pleats.

Vacuum Cleaning
Vacuum cleaning is another method for cleaning primary air lter elements which require daily cleaning because of a dry, dusty environment. Cleaning with pressurized air is recommended prior to vacuum cleaning. Vacuum cleaning will not remove deposits of carbon and oil.

Pressurized air Vacuum cleaning

74 Maintenance Section Engine Air Filter Secondary Element - Replace

KEBU7534-03

Inspecting the Primary Air Filter Elements

Do not use paint, a waterproof cover, or plastic as a protective covering for storage. An airow restriction may result. To protect against dirt and damage, wrap the primary air lter elements in Volatile Corrosion Inhibited (VCI) paper. Place the primary air lter element into a box for storage. For identication, mark the outside of the box and mark the primary air lter element. Include the following information:

Date of cleaning Number of cleanings

Store the box in a dry location.
Illustration 79
g00281693 i02080824

Inspect the clean, dry primary air lter element. Use a 60 watt blue light in a dark room or in a similar facility. Place the blue light in the primary air lter element. Rotate the primary air lter element. Inspect the primary air lter element for tears and/or holes. Inspect the primary air lter element for light that may show through the lter material. If it is necessary in order to conrm the result, compare the primary air lter element to a new primary air lter element that has the same part number. Do not use a primary air lter element that has any tears and/or holes in the lter material. Do not use a primary air lter element with damaged pleats, gaskets or seals. Discard damaged primary air lter elements.

Engine Air Filter Secondary Element - Replace

SMCS Code: 1054-510-SE NOTICE Always replace the secondary lter element. Never attempt to reuse the secondary lter element by cleaning the element. When the primary lter element is replaced, the secondary lter element should be replaced. The secondary lter element should also be replaced if the exhaust smoke is still black. 1. Open the engine compartment. 2. See Operation and Maintenance Manual, Engine Air Filter Primary Element - Clean/Replace. Remove the air cleaner cover from the air cleaner housing. Remove the primary lter element from the air cleaner housing.

Storing Primary Air Filter Elements

If a primary air lter element that passes inspection will not be used, the primary air lter element can be stored for future use.

Illustration 80

g00281694

Illustration 81

g00101451

3. Remove the secondary lter element.

KEBU7534-03

75 Maintenance Section Engine Air Filter Service Indicator - Inspect

4. Cover the air inlet opening. Clean the inside of the air cleaner housing. 5. Remove the cover from the air inlet opening. 6. Install the new secondary lter element. 7. Install the primary lter element. 8. Install the air cleaner cover and close the latches securely. 9. Close the engine compartment.
i02055014

8. Close the engine compartment.

i01404793

Engine Compartment - Clean

SMCS Code: 1000-070 NOTICE Before spraying the engine compartment with high pressure water turn off the engine and allow the engine to cool. Do not spray water directly on a hot fuel injection pump or damage may occur. Use a commercially available engine degreaser in order to clean the engine compartment. Use caution and minimize the water around bearings and electrical connections.
i02055145

Engine Air Filter Service Indicator - Inspect

SMCS Code: 7452-040

Engine Oil Level - Check

SMCS Code: 1348-535-FLV NOTICE Do not under ll or overll engine crankcase with oil. Either condition can cause engine damage. Stop the engine in order to check the oil level. DO NOT check the oil level when the engine is running. Park the machine on a level surface.
Illustration 82
g01053780

1. Open the engine compartment.

1. Open the engine compartment. 2. Clean the air intake system. a. Squeeze rubber ap (2)in order to remove dirt from the dust ejector. 3. Start the engine. 4. Run the engine at high idle. 5. If the yellow piston in engine air lter service indicator (1) enters the red zone, service the air cleaner. 6. Press the end of the indicator in order to reset the indicator after the air cleaner has been serviced. 7. Stop the engine. Note: See the Operation and Maintenance Manual, Engine Air Filter Primary Element - Clean/Replace. See the Operation and Maintenance Manual, Engine Air Filter Secondary Element - Replace.
g01053858

Illustration 83

76 Maintenance Section Engine Oil Sample - Obtain

KEBU7534-03

2. Remove dipstick (2). Wipe the dipstick with a clean cloth. Insert the dipstick. Remove the dipstick and note the oil level. Insert the dipstick. Note: Refer to the Operation and Maintenance Manual, Lubricant Viscosities for more information on the correct grade of engine oil to use. Refer to Operation and Maintenance Manual, Capacities (Rell) for the correct amount of oil that is used when the oil is changed. The correct amount of oil determines the correct level of the oil in the FULL range on the dipstick. NOTICE Do not overll the crankcase. The oil level must not reach the top of the FULL range mark or above the FULL range mark. 3. Maintain the oil level on the dipstick between the FULL RANGE mark and the ADD OIL mark . Add oil if the oil level is too low. Note: Operating your engine with the oil level above the FULL mark in the FULL Range could cause the crankshaft to dip into the oil. This could result in excessively high operating temperatures. The high operating temperatures could result in reduced lubricating characteristics of the oil. This could cause damage to the bearings and loss of engine power. 4. If the oil level is correct, close the engine compartment.

Illustration 84

g01053869

Obtain a sample of the engine oil from engine oil sampling valve (1) that is located on the engine oil lter housing. Refer to Special Publication, SEBU6250, SOS Oil Analysis for information that pertains to obtaining a sample of the engine oil. Refer to Special Publication, PEHP6001, How To Take A Good Oil Sample for more information about obtaining a sample of the engine oil.
i02055163

Add The Engine Oil

1. Remove oil ller cap (1). 2. Add the oil so that the oil is at the correct level. 3. Clean the oil ller cap. Install the oil ller cap. 4. Close the engine compartment.
i02055157

Engine Oil and Filter - Change

SMCS Code: 1318-510 Run the engine in order to warm up the oil. Stop the engine before you drain the oil. When the oil is warm the waste particles are suspended in the oil. The waste particles will be removed when the oil is drained. As the oil cools, the waste particles settle to the bottom of the oil pan. The waste particles will not be removed if the oil is too cool. The waste particles can recirculate through the engine lubrication system if the recommended procedure is not followed. 1. Open the engine compartment.

Engine Oil Sample - Obtain

SMCS Code: 1000-008

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.

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77 Maintenance Section Engine Valve Lash - Check

10. Before you start the engine, check the oil level on dipstick (3). The oil level must be within the FULL RANGE on the dipstick. 11. Start the engine. Run the engine for two minutes. Inspect the machine for leaks. Stop the machine. 12. Wait for ten minutes in order to allow the oil to drain back into the crankcase. Check the oil level. Maintain the oil level within the FULL RANGE on the dipstick. 13. Close the engine compartment.
Illustration 85
g01053873 i01897328

Some components have been removed in order to clearly show the components. (1) (2) (3) (4) Oil ller cap Filter element Dipstick Drain valve

Engine Valve Lash - Check

SMCS Code: 1105-535 Note: A qualied service person should perform the valve lash check and/or the valve lash adjustment. Special tools and training are required. Refer to your machines Service Manual for complete instructions.
i02075239

2. Place a suitable container under the drain valve. Open drain valve (4). Refer to the Operation and Maintenance Manual, General Hazard Information for information that pertains to containing uid spillage. 3. Allow the oil to completely drain. 4. Close drain valve (4). 5. Remove lter element (2). Note: Dispose of the used lter element according to local regulations. 6. Clean the lter housing base. All of the old lter seal must be removed from the lter housing base. 7. Apply a thin coat of engine oil to the seal of the new lter element. 8. Install the new lter by hand. When the seal contacts the base, tighten the lter element for an additional 3/4 turn. This will tighten the lter sufciently. Every new oil lter has rotation index marks that are spaced at 90 degree increments. Use the rotation index marks as a guide for tightening the oil lter. 9. Remove oil ller cap (1). Fill the crankcase with new oil. See Operation and Maintenance Manual, Capacities (Rell). See Operation and Maintenance Manual, Lubricant Viscosities. Clean the oil ller cap and install the oil ller cap.

Engine Water Pump - Inspect

SMCS Code: 1361-040 A water pump that has failed might cause severe engine overheating. Severe engine overheating could result in the following problems:

Cracks in the cylinder head Piston seizure Other potential engine damage
Open the engine compartment.

Illustration 86

g01061939

78 Maintenance Section Fuel System - Prime

KEBU7534-03

Water pump (1) is located on the engine block at the front of the engine. Visually inspect the water pump for leaks. If leaks are found, all the seals must be replaced.
i02090480

i02055321

Fuel System Water Separator Element - Replace

SMCS Code: 1263-510-FQ 1. Open the engine compartment.

Fuel System - Prime

SMCS Code: 1250-548 This machines engine is equipped with an electronic fuel pump. Turn the engine start key to the ON position in order to prime the fuel system. Check for leaks.
i02055316

Fuel System Water Separator - Drain

SMCS Code: 1263-543 1. Open the engine compartment. 2. The water separator is located in the engine compartment on the back of the machine.
Illustration 88
g01054044

2. Open drain valve (2). Allow the fuel, the water and sediment to drain into a suitable container. 3. Remove housing (1) from the mounting base. 4. Remove the seal for housing (1). 5. Remove the lter element from housing (1). 6. Install the new lter element into housing (1). 7. Install a new seal for housing (1). 8. Install housing (1) onto the base. 9. Turn the engine start key to the ON position in order to prime the fuel system. Check for leaks.

Illustration 87

g01054032

10. Close the engine compartment.

i02066954

3. Open drain valve (1) that is located on the bottom of the separator element. Allow the water and sediment to drain into a suitable container. 4. Close drain valve (1). 5. If the engine fails to start, change the fuel lter. If there is a power loss, change the fuel lter. 6. Close the engine compartment.

Fuel Tank Cap Filter and Strainer - Replace/Clean

SMCS Code: 1273-070-Z2; 1273-070-STR; 1273-510-FI 1. The fuel tank is located on the rear of the machine.

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79 Maintenance Section Fuel Tank Water and Sediment - Drain

i02066986

Fuel Tank Water and Sediment - Drain

SMCS Code: 1273-543-M&S

Illustration 89

g00896029

2. Lift lever (1) and turn lever (1) counterclockwise until the lever stops. Remove the cap. 3. Inspect seal (2) for damage. Replace the seal, if necessary. 4. Inspect lters (3). Clean the lters. Replace the lters, if necessary.
g00893445

Illustration 91

The drain valve is located on the bottom of the fuel tank. Drain the water and the sediment into a suitable container. Refer to the Operation and Maintenance Manual, General Hazard Information for information that pertains to containing uid spillage. Close the drain valve. Note: Dispose of all uids according to local regulations.
i02050186

Fuses - Replace
SMCS Code: 1417-510
Illustration 90
g01059072

5. Remove the strainer that is located in the ller opening. 6. Wash the strainer and the fuel tank cap in a clean, nonammable solvent. 7. Apply a thin lm of fuel to the gasket of the fuel tank cap. 8. Install the fuel tank cap.

Fuse The fuses protect the electrical system from damage that is caused by overloaded circuits. Change the fuse if the element separates. If the element of the new fuse separates, check the circuit. Repair the problem before you operate the machine. NOTICE Replace fuses with the same type and size. Improper use of fuses could result in electrical damage. Frequent replacement of fuses may indicate another type of electrical problem. Contact your Caterpillar dealer.

80 Maintenance Section Hydraulic System Oil - Change

KEBU7534-03

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products.
Illustration 92
g01051671

Dispose of all uids according to local regulations and mandates. Note: Cleanliness must be a priority when you change the hydraulic oil. Note: Change the oil in a clean work area. Use clean tools. Make sure that you have clean hands. 1. Operate the machine enough to warm the oil. The machine should be level with the parking brake engaged and the engine stopped. 2. Open the engine compartment.

Backup Alarm (1) 10 amp Glow Plugs (2) 10 amp Flashers (3) 10 amp Pump for Tire Ination (4) 10 amp Keyswitch (5) 10 amp Parking Brake (6) 10 amp Traction Control (7) 10 amp Gauges (8) 10 amp Water Spray System (9) 10 amp
i02055342

Hydraulic System Oil - Change

SMCS Code: 5050-044; 5056-044

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin.

Illustration 93

g00893381

3. Remove the hydraulic tank ller cap.

KEBU7534-03

81 Maintenance Section Hydraulic System Oil Filter - Replace

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products.
Illustration 94
g01062438

Dispose of all uids according to local regulations and mandates. NOTICE Take extreme care to insure the cleanliness of the hydraulic oil. Keep the hydraulic oil clean in order to extend the component life and assure the maximum performance. 1. Open the engine compartment.

4. Remove the drain plug from the bottom of the hydraulic tank. Drain the oil to a suitable container. Allow the oil to drain until the hydraulic tank is empty. 5. Install the drain plug. 6. Fill the hydraulic tank with clean, approved hydraulic oil. Refer to the Operation and Maintenance Manual, Lubricant Viscosities and Operation and Maintenance Manual, Capacities (Rell) for more information. Clean the hydraulic tank ller cap and install the ller cap. 7. Start the engine and allow the oil to warm. Stop the engine. 8. Refer to illustration 93. Maintain the proper oil level in the sight gauge. This level is between the FULL mark and the ADD mark on the decal next to the sight glass. 9. Close the engine compartment.

Illustration 95
i02055354

g00893381

Hydraulic System Oil Filter Replace

SMCS Code: 5068-510

2. Remove the hydraulic tank ller cap.

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin.

82 Maintenance Section Hydraulic System Oil Level - Check

KEBU7534-03

Illustration 97

g00892871

2. Maintain the proper oil level in the sight gauge. This level is between the FULL mark and the ADD mark on the decal next to the sight glass.
Illustration 96
g01054087

3. Close the engine compartment.

i02055511

3. The hydraulic oil lter is located toward the right side of the machine. 4. Clean the hydraulic oil lter location. 5. Remove the lter with a strap type wrench. 6. Clean the lter housing base. Remove any existing gasket material. 7. Apply a light coat of hydraulic oil to the gasket on the new lter. 8. Use your hand to install the new lter. When the seal contacts the base, tighten the lter element for an additional three quarters of a turn. 9. With the machine on level ground, check the hydraulic oil level in the sight gauge. The oil level should be visible in the sight gauge. 10. Add required oil. Refer to Operation and Maintenance Manual , Hydraulic System Oil Level - Check. 11. Close the engine compartment.
i01744155

Hydraulic System Oil Sample - Obtain

SMCS Code: 5056-008

Illustration 98

g01054156

Hydraulic System Oil Level Check

SMCS Code: 5056-535-FLV; 5095-535-FLV 1. Open the engine compartment.

The sampling port for the hydraulic oil is located on the inlet line for the hydraulic oil lter. Refer to Special Publication, SEBU6250, SOS Oil Analysis for information that pertains to obtaining a sample of the hydraulic oil. Refer to Special Publication, PEHP6001, How To Take A Good Oil Sample for more information about obtaining a sample of the hydraulic oil.

KEBU7534-03

83 Maintenance Section Hydraulic System Tank Vent - Replace

i02074965

Hydraulic System Tank Vent Replace

SMCS Code: 5056-510-BRE; 5118-510

3. Clean the strainer in clean, nonammable solvent. Dry the strainer with compressed air. 4. Install the strainer and the ller cap.
i01746601

Indicators and Gauges - Test

SMCS Code: 7450-081 1. Open the engine compartment.

Illustration 99

g01061754

1. Open the engine compartment. Note: The vent is located on top of the hydraulic tank. 2. Remove the vent from the hydraulic tank. 3. Install a new vent. 4. Close the engine compartment.
i02072906

Illustration 101 Right rear of machine

g00894148

2. Turn the battery disconnect switch ON.

Hydraulic Tank Strainer - Clean

SMCS Code: 5056-070-STR

Illustration 102

g00894151

3. Look for broken gauges (1), indicator lights, or switches on the instrument panel. 4. Do not start the engine, but turn the key start switch (2) to ON. The alternator indicator light (3) and the parking brake indicator light (4) should be on. 5. Observe any gauges that do not operate. Make any needed repairs before operating the machine.

Illustration 100

g01059072

1. Remove the ller cap for the hydraulic tank. 2. Pull the strainer for the hydraulic tank out of the ller tube.

84 Maintenance Section Neutral Start Switch - Test

KEBU7534-03

i02055530

Neutral Start Switch - Test

SMCS Code: 1424-025; 1424-081; 1424-535

5. Place propel lever (1) in the REVERSE position. Repeat steps 3 through 4.
i02106227

Oil Filter - Inspect

The machine may lurch forward if the neutral start switch is out of adjustment. Be sure the area is clear of all personnel and equipment before performing this test. 1. Turn the battery disconnect switch clockwise in order to turn the electrical system ON. SMCS Code: 1308-507; 3004-507; 3067-507; 5068-507

Inspect a Used Filter for Debris

Illustration 105 The element is shown with debris.

g00894258

g00100013

Illustration 103

2. Place propel lever (1) in the FORWARD position.

Use a lter cutter to cut the lter element open. Spread apart the pleats and inspect the element for metal and for other debris. An excessive amount of debris in the lter element can indicate a possible failure. If metals are found in the lter element, a magnet can be used to differentiate between ferrous metals and nonferrous metals. Ferrous metals can indicate wear on steel parts and on cast iron parts. Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings, rod bearings, or turbocharger bearings. Small amounts of debris may be found in the lter 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 lter 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 unltered oil. The particles could enter the lubricating system and the particles could cause damage.

Illustration 104

g01054175

3. Hold engine start switch (2) in the START position. Slowly move the propel lever toward the NEUTRAL position. 4. If the engine starts before you move the propel lever to the NEUTRAL position, the neutral start switch requires adjustment. Do not operate the machine until the repairs have been made. Refer to the service manual for your machine for instructions on adjusting the neutral start switch.

KEBU7534-03

85 Maintenance Section Oscillating and Steering Bar - Lubricate

i01749852

Oscillating and Steering Bar Lubricate

SMCS Code: 4313-086

Kingpin Bearing Lubrication

Illustration 107 Illustration 106 Lubrication point for kingpin assembly

g00896079

g01054185

1. Wipe all ttings, caps and plugs before servicing. 2. Lubricate the tting for the oscillating and steering bar, as shown.
i02055537

The radiator core is located directly behind the hydraulic oil cooler. Inspect the hydraulic oil cooler and the radiator core for debris. If necessary, clean the hydraulic oil cooler and the radiator core. Compressed air is preferred, but high pressure water or steam can be used to remove dust and general debris from the oil cooler and the radiator core. Clean the cores according to the condition of the cores. Note: High pressure water can bend the oil cooler and the radiator ns. See Special Publication, SEBD0518, Know Your Cooling System for more detailed information about cleaning radiator ns. Close the engine compartment.

Radiator and Hydraulic Oil Cooler - Clean

SMCS Code: 1353-070-KO; 1374-070 NOTICE High pressure water can damage the radiator. Use a water spray nozzle on the pressure washer that will disperse the water pressure. Open the engine compartment.

86 Maintenance Section Rollover Protective Structure (ROPS) - Inspect

KEBU7534-03

i02055555

Rollover Protective Structure (ROPS) - Inspect

SMCS Code: 7323-040

Illustration 109 Typical example

g00932801

Illustration 108

g01054212

Check the seat belt mounting hardware (1) for wear or for damage. Replace any mounting hardware that is worn or damaged. Make sure that the mounting bolts are tight. Check buckle (2) 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 ve years of the date of manufacture, replace the seat belt. Replace the seat belt at the date which occurs rst. 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.
i02429594

Inspect the rollover protective structure (ROPS) for cracks. Inspect the rollover protective structure (ROPS) for any loose bolts or for damaged bolts. Replace the damaged bolts with original equipment parts only. Tighten the mounting bolts for the ROPS to a torque of 800 100 Nm (592 74 lb ft). There is a total of 16 mounting bolts for the ROPS. The mounting bolts for the ROPS are located at the bottom of the post for the ROPS. Do not straighten the ROPS or do not repair the ROPS by welding reinforcement plates to the ROPS. Consult your Caterpillar dealer for the repair of the ROPS.
i02429589

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.

Seat Belt - Replace

SMCS Code: 7327-510 Within three years of the date of installation or within ve years of the date of manufacture, replace the seat belt . Replace the seat belt at the date which occurs rst. 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.

KEBU7534-03

87 Maintenance Section Steering Cylinder Ends - Lubricate

i02055592

Strainer (Flushing System) Clean

SMCS Code: 5050-070-STR

Personal injury can result from hydraulic oil pressure and hot oil.
Illustration 110 (1) Date (2) Date (3) Date (4) Date of installation (retractor) of installation (buckle) of manufacture (tag) (fully extended web) of manufacture (underside) (buckle)
g01152685

Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil ller cap only when the engine is stopped, and the ller cap is cool enough to touch with your bare hand. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. Park the machine on a level surface. Ensure that the parking brake is fully engaged. Shut off the engine. Remove the oil ller cap for the hydraulic tank. The strainer for system ushing is located inside the engine compartment on left side of the machine.

Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware. If your machine is equipped with a seat belt extension, also perform this replacement procedure for the seat belt extension.
i01743968

Steering Cylinder Ends Lubricate

SMCS Code: 4303-086-BD; 4303-086

Steering Cylinder

Illustration 111 Right side of machine

g00892786

1. Lubricate one tting on each end of the steering cylinder from each side of the machine.

88 Maintenance Section Tire Ination - Check

KEBU7534-03

Inate the tires, if necessary. See Operation and Maintenance Manual, Tire Ination Information for information about tire ination, tire pressures, and tire ination pressure adjustment.
i01747479

Tire Mat - Replace

SMCS Code: 6611-510

Illustration 112

g01005311

1. Loosen top hose (1) and cap the hose. Remove cover (2). 2. Remove the strainer from the housing. 3. Clean the strainer. Use a nonammable solvent in order to clean the strainer. If the strainer is damaged, replace the strainer. Consult your Caterpillar dealer for replacement parts. 4. Install the strainer. 5. Install cover (2) and top hose (1). Install the oil ller cap for the hydraulic tank.
i01784823

Block the machine in order to prevent unexpected movement of the machine. Failure to do so may result in personal injury or death.

Illustration 113

g00894669

Tire Ination - Check

SMCS Code: 4203-535-PX

1. Remove the bolts and remove the damaged mat. 2. Install the new mat. Install the bolts.
i02064840

Personal injury can result from improper tire ination. A tire blowout or rim failure can result from improper or misused equipment. Use a self-inating chuck and stand behind the tread when inating a tire. Proper inating equipment, and training in using the equipment, are necessary to avoid overinating. Before inating tire, put the tire in a restraining device. Measure the tire pressure on each tire. Consult your Caterpillar dealer for the correct load rating and for the correct operating pressures.

Tire Scraper - Inspect/Adjust/ Replace

SMCS Code: 6607-025; 6607-040; 6607-510

Block the machine in order to prevent unexpected movement of the machine. Failure to do so may result in personal injury or death.

KEBU7534-03

89 Maintenance Section Toggle Switch - Inspect

1. Turn the engine start switch to the OFF position. Do not test the switches when the machine is running. 2. Visually inspect the area around the seal (3). Look for cracks or splits on the seal. If any cracks or splits are noticed, replace the switch. 3. Lightly move the toggle switch (1) in order to test for free play. If the switch moves more than 2 mm (0.01 inch) in either direction, replace the switch. 4. Press the switch upward. The toggle switch (1) should displace approximately 5 mm (0.2 inch). If the switch has an incorrect displacement, replace the switch. Repeat the measurement when you press the switch downward.
i02137293

Illustration 114

g00894685

Inspect tire scrapers (1) and clean the scrapers. Adjust tire scrapers (1) so that the tire scrapers are centered across the tire. Replace the tire scrapers if the tire scrapers are damaged. 1. Loosen the bolts (2) that fasten the tire scrapers. 2. Remove the damaged tire scraper (1). 3. Install the new tire scraper. 4. Tighten the bolts on the new tire scraper. 5. Adjust the new tire scraper so that the new tire scraper is centered across the tires.
i02711091

Water Spray Nozzles - Clean

SMCS Code: 6609-070

Toggle Switch - Inspect

SMCS Code: 7332-040
Illustration 116 Rear spray nozzles

g00910743

Illustration 115 (1) Switch in neutral position (2) Displaced switch (3) Seal

g01360853

Illustration 117 Front spray nozzles

g00910744

1. Remove the caps and the screens. 2. Clean the screens in nonammable solvent.

Perform the following steps in order to inspect the switches on your machine.

90 Maintenance Section Water Spray System - Drain

KEBU7534-03

3. Install the screens and caps.

i01742647

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Water Spray System - Drain

SMCS Code: 5612-543 NOTICE Drain the water spray system completely when freezing conditions exist. This is done in order to avoid damage to the water spray system.

Water Spray System Filter Clean

SMCS Code: 5612-070-FI NOTICE Drain the water spray system completely when freezing conditions exist. This is done in order to avoid damage to the water spray system. 1. Remove the drain plug in order to drain the water tank. See Operation and Maintenance Manual, Water Spray System - Drain.

Illustration 118

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1. Remove the drain plug from the water tank.

Illustration 120 Water lter (if equipped)

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2. The water lter is located under the water tank on the front side of the machine. 3. In order to remove the lter bowl, turn the lter bowl in a counterclockwise direction. 4. Remove the screen from the lter bowl. 5. Wash the lter bowl and the screen in clean, nonammable solvent. Dry the components with pressure air.
Illustration 119
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6. Replace any components that are damaged. 7. Reverse the removal steps in order to install the water spray system lter. 8. Install the drain plug in the water tank. 9. Fill the water tank with clean water. See Operation and Maintenance Manual, Capacities (Rell).

2. Remove the water lter, if equipped. 3. Install the water lter and install the drain plug. 4. Close the valve.

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91 Maintenance Section Water Tank Strainer - Clean and Inspect

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Water Tank Strainer - Clean and Inspect

SMCS Code: 5613-571-STR

Wheel Bearings (Front) Lubricate

SMCS Code: 3282-086-BD; 4208-086

Accidental machine starting can cause injury or death to personnel working on the machine. To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps.
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Illustration 121

Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

1. Remove the ller cap. 2. Remove the strainer. 3. Clean the ller cap with clean water or compressed air. 4. Clean the strainer with clean water or compressed air. 5. Install the strainer. 6. Fill the tank with clean water. 7. Install the ller cap.
Illustration 122
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1. Wipe all ttings, caps, and plugs before servicing.

Illustration 123 Front wheels

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2. Use the hydraulic ttings and lubricate each of the wheel bearings (ve wheels).

92 Maintenance Section Wheel Nuts - Tighten

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Wheel Nuts - Tighten

SMCS Code: 4210-527

Accidental machine starting can cause injury or death to personnel working on the machine. To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps. Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

Illustration 124

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1. Tighten the front wheel bolts to a torque of 155 14 Nm (115 10 lb ft). 2. Tighten the rear wheel nuts to a torque of 238 20 Nm (175 15 lb ft).