2010 Caterpillar
All Rights Reserved
KEBU7519-08
July 2009
Operation and
Maintenance
Manual
CP-533E and CS-533E Vibratory Soil
Compactors
BZE1-Up (Machine)
TBE1-Up (Machine)
BZG1-Up (Machine)
TLH1-Up (Machine)
DAK1-Up (Machine)
ASL1-Up (Machine)
TJL1-Up (Machine)
ASM1-Up (Machine)
DAM1-Up (Machine)
SAFETY.CAT.COM
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Maintenance Section
Maintenance Interval Schedule
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When Required
Battery - Clean/Check ........................................... 68
Battery - Recycle .................................................. 68
Battery or Battery Cable - Inspect/Replace .......... 69
Circuit Breakers - Reset ........................................ 71
Drum Cooling Oil - Change ................................... 77
Drum Scrapers - Inspect/Adjust/Replace .............. 78
Engine Air Filter Primary Element - Clean/
Replace ............................................................... 81
Engine Air Filter Secondary Element - Replace ... 83
Engine Compartment - Clean ............................... 84
Fuses - Replace .................................................... 92
Oil Filter - Inspect .................................................. 97
Radiator Core - Clean ........................................... 98
Wheel Nuts - Tighten .......................................... 104
Window Washer Reservoir - Fill .......................... 104
Window Wiper - Inspect/Replace ........................ 104
Windows - Clean ................................................. 104
68
73
84
85
91
94
95
96
99
67
86
90
90
95
97
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Maintenance Section
Maintenance Interval Schedule
Every Year
Cooling System Coolant Sample (Level 2) Obtain ................................................................. 74
Refrigerant Dryer - Replace .................................. 98
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Maintenance Section
Axle Oil (Rear) - Change
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Illustration 71
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Illustration 72
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Illustration 73
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Maintenance Section
Backup Alarm - Test
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Battery - Clean/Check
SMCS Code: 1401-535
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Illustration 75
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Illustration 74
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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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Maintenance Section
Battery or Battery Cable - Inspect/Replace
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Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510
Illustration 76
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Illustration 77
(1)
(2)
(3)
(4)
(5)
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Maintenance Section
Cab Air Filter - Clean/Replace
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Alternator Belt
1. To check the belt tension, apply 110 N (25 lb)
of force midway between the pulleys. Correctly
adjusted belts will deflect 14 to 20 mm
(1/2 to 3/4 inch).
2. In order to adjust the alternator belt, loosen
bracket bolt (2) and mounting bolt (1) on the
alternator bracket.
3. To achieve the correct adjustment, move the
alternator inward or move the alternator outward,
as required.
4. Tighten mounting bolt (1) and bracket bolt (2).
Illustration 78
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Illustration 79
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Maintenance Section
Circuit Breakers - Reset
Illustration 81
(1)
(2)
(3)
(4)
(5)
(6)
Illustration 80
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Bolts
Radiator cap
Cooler
Drain valve
Expansion tank
Cap for the expansion tank
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Maintenance Section
Cooling System Coolant (ELC) - Change
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
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.
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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 specifications 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.
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Maintenance Section
Cooling System Coolant Extender (ELC) - Add
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Illustration 82
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Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
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Illustration 83
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bags.
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Illustration 84
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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.
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Maintenance Section
Cooling System Pressure Cap - Clean/Replace
Illustration 85
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Illustration 86
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Maintenance Section
Cooling System Water Temperature Regulator - Replace
NOTICE
Failure to replace the engine's 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.
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NOTICE
The water temperature regulators may be reused if the
water temperature regulators are within test specifications, 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.
Illustration 87
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Illustration 88
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Maintenance Section
Crankshaft Vibration Damper - Inspect
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Illustration 90
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Illustration 89
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Typical example
The Crankshaft Vibration Damper
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Maintenance Section
Drum Scrapers - Inspect/Adjust/Replace
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Illustration 91
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Steel Scrapers
Adjust
Adjust
Flexible Scrapers
There is a scraper on the front of the drum and there
is a scraper on the rear of the drum.
Adjust
1. Inspect flexible scraper (2). Clean the flexible
scraper of dirt and debris.
2. Loosen bolts (1) that are holding the rear flexible
scraper blade and the backing plate to the bracket.
3. Loosen bolts (1) that hold the front flexible scraper
blade and the backing plate to the bracket.
Note: When you adjust flexible scraper (3), steel
backing plate (2) must not come into contact with the
surface of the drum.
Illustration 92
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Maintenance Section
Eccentric Weight Housing Oil - Change
Illustration 94
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Illustration 93
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Maintenance Section
Eccentric Weight Housing Oil - Change
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Illustration 96
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Illustration 98
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Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
Illustration 99
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Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
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Pressurized Air
Pressurized air can be used to clean primary air filter
elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi).
Pressurized air
Vacuum cleaning
Illustration 100
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Vacuum Cleaning
Vacuum cleaning is another method for cleaning
primary air filter elements which require daily cleaning
because of a dry, dusty environment. Cleaning with
pressurized air is recommended prior to vacuum
cleaning. Vacuum cleaning will not remove deposits
of carbon and oil.
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Maintenance Section
Engine Air Filter Secondary Element - Replace
Date of cleaning
Number of cleanings
Store the box in a dry location.
Illustration 101
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Illustration 102
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Illustration 103
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Maintenance Section
Engine Air Filter Service Indicator - Inspect
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Illustration 104
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Illustration 105
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Maintenance Section
Engine Oil Level - Check
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Illustration 106
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Illustration 107
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Maintenance Section
Engine Oil and Filter - Change
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Illustration 109
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(4) Dipstick
Illustration 108
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10. Before you start the engine, check the oil level on
dipstick (4). The oil level must be within the FULL
RANGE on the dipstick.
11. Start the engine. Run the engine for two minutes.
Inspect the machine for leaks. Stop the machine.
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Maintenance Section
Engine Water Pump - Inspect
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Illustration 110
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Maintenance Section
Final Drive Planetary (Axle) Oil Level - Check
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Illustration 113
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Illustration 114
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Maintenance Section
Final Drive Planetary (Drum) Oil - Check
Illustration 115
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Illustration 116
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Illustration 117
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90
Maintenance Section
Fuel System Primary Filter (Water Separator) - Replace
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S/N: BZE1-Up
S/N: TBE1-Up
S/N: BZG1-Up
S/N: TLH1-Up
S/N: DAK1-Up
S/N: TJL1-Up
S/N: ASL1-Up
S/N: TJL1-Up
S/N: ASM1-Up
S/N: DAM1-Up
1. Open the engine compartment.
The water separator element is located in the
engine compartment on the right side of the
machine.
Illustration 118
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2. Open drain valve (2). Allow the fuel, the water and
sediment to drain into a suitable container.
3. Remove housing (3) from the mounting base.
4. Remove the seal for housing (3).
5. Remove the filter element from housing (3).
6. Install the new filter element into housing (3).
Illustration 119
(1)
(2)
(3)
(4)
(5)
(6)
Screw
Element
Glass bowl
Sensor connection
Drain
Bottom cover
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Maintenance Section
Fuel System Water Separator - Drain
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Illustration 120
Illustration 121
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Maintenance Section
Fuel Tank Water and Sediment - Drain
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Fuses - Replace
SMCS Code: 1417-510
Illustration 122
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Illustration 124
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Illustration 125
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Maintenance Section
Hydraulic System Oil - Change
(16) Spare
(4) Horn
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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.
(13) Spare
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(14) Spare
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Maintenance Section
Hydraulic System Oil Filter - Replace
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Illustration 127
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Illustration 129
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Illustration 128
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Illustration 130
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Maintenance Section
Hydraulic System Oil Sample - Obtain
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Illustration 132
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Illustration 133
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Maintenance Section
Isolation Mounts - Inspect
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Illustration 135
Illustration 134
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Illustration 136
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Maintenance Section
Oil Filter - Inspect
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Illustration 137
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Illustration 138
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Maintenance Section
Radiator Core - Clean
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Illustration 140
Illustration 139
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Maintenance Section
Seat Belt - Inspect
Illustration 142
Illustration 141
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Typical example
(1)
(2)
(3)
(4)
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Maintenance Section
Steering Cylinder Ends - Lubricate
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Illustration 145
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Illustration 144
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Illustration 146
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Maintenance Section
Tire Inflation - Check
Table 11
Ply
Rating
Low
Pressure
Limit
12
16
16
30
10
12
16
20
30
12
12
16
24
30
14
12
16
28
30
Normal
High
Operating Pressure
Pressure
Limit
Maximum
Shipping
Pressure
Liquid Ballast
The liquid ballast for tires is a solution of water and
calcium chloride powder CaCl2. Calcium chloride
powder CaCl2 is an additive which will provide an
antifreeze protection and additional weight. If a tire is
repaired or replaced, the tire must be filled with the
correct amount of liquid ballast before the machine
returns to operation. The correct mixture for the liquid
ballast is 300 grams of calcium chloride powder
CaCl2 per 1 Liter of water. Fill each tire with 430 L
(114 US gal) of thirty percent calcium chloride and
seventy percent water.
1. Move the machine to a flat surface and park the
machine with the valve stem in the 9 o'clock
position.
2. Remove the cap for the valve stem.
3. Check for fluid by depressing the stem in the valve
stem. The liquid ballast should spray from the
stem.
4. Move the machine so that the valve stem is in the
11 o'clock position.
5. Depress the stem in the valve stem. A light mist
should spray from the valve stem.
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Maintenance Section
Vibratory Support Oil - Change
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Illustration 147
Illustration 149
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Illustration 150
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Illustration 148
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6. Clean plugs (2) and (3). Install plugs (2) and (3).
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Maintenance Section
Vibratory Support Oil Level - Check
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Illustration 153
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Illustration 152
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Illustration 154
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Maintenance Section
Wheel Nuts - Tighten
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Illustration 155
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Illustration 157
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Windows - Clean
SMCS Code: 7310-070
Use commercially available window cleaning
solutions in order to clean the windows. Clean the
outside of the cab windows from the ground unless
handholds are available.
Illustration 156
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