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MAINTENANCE INTERVALSOperation and MaintenanceManual Excerpt

2010 Caterpillar

All Rights Reserved

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KEBU!0"#01$epte%&er 2001

Operation andMaintenance

ManualCS-531D C!-533D and CS-533DVi"rator# Co$pactor%

A&C1-'p (Mac)ine*A+,1-'p

(Mac)ine*AET1-'p(Mac)ine*

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"Maintenance $ectionMaintenance 'nterval $chedule

i01"002!1

Maintenance InteralSc)edule

SMCS Code. 1000( 000

/)en Re0uired

Batter) # Rec)cle***************************************************+0Ca& Air ,ilter # Clean-Replace*******************************+2Circuit Brea.ers # Reset****************************************+/Cutting Edges eveling Blade # 'nspect-Replace***************************************************************3/

4ru% Cooling Oil # Change***********************************354ru% $crapers # 'nspect-Ad6ust-Replace**************3!Engine Air ,ilter 7ri%ar) Ele%ent #Clean-Replace***************************************************101

Engine Air ,ilter $econdar) Ele%ent # Replace **102Ether $tarting Aid C)linder # Replace***********103

,uel $)ste% # 7ri%e********************************************112,uel $)ste% 8ater $eparator # 4rain******************11",uses # Replace**************************************************113Oil ,ilter # 'nspect************************************************12"Radiator Core # Clean*****************************************12"8heel 9uts # :ighten*******************************************1/18indo; 8asher Reservoir # ,ill**************************1/28indo; 8iper # 'nspect-Replace************************1/28indo;s # Clean*************************************************1/2

Eer# 1 Serice ,our% or Dail#

Bac.up Alar% # :est**********************************************3Cooling $)ste% evel # Chec.******************************30

Engine Air ,ilter $ervice 'ndicator # 'nspect********10/Engine Oil evel # Chec.*************************************10!

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Maintenance

$ectionMaintenance 'nterval

4ru% $upport Oil # Chec.*************************************3Engine Oil $a%ple # O&tain*********************************10"Engine Oil and ,ilter # Change****************************10,inal 4rive 7lanetar) Axle Oil evel # Chec.*****111,inal 4rive 7lanetar) 4ru% Oil # Chec.************112?i&rator) $upport Oil evel # Chec.********************1/0

Eer# 5 Serice ,our% or 4 Mont)%Axle Oil $a%ple # O&tain*******************************************************************************3Cooling $)ste% Coolant $a%ple # O&tain*******************************************************************************+34ru% $upport Oil $a%ple # O&tain***********************3,inal 4rive 7lanetar) Axle Oil $a%ple #O&tain****************************************************************111,inal 4rive 7lanetar) 4ru% Oil $a%ple #O&tain****************************************************************112,uel $)ste% 7ri%ar) ,ilter # Clean-'nspect-

Replace***********************************************************11/,uel $)ste% $econdar) ,ilter # Replace*************115,uel $)ste% 8ater $eparator Ele%ent #Replace*************************************************************11"

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Engine 8ater 7u%p # 'nspect******************************103

Eer# 3 ear%

$eat Belt # Replace**********************************************12

Eer# 3 Serice ,our% or 3 ear%Cooling $)ste% Coolant Extender EC # Add******++Eccentric 8eight

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3Maintenance

$ectionAxle Oil $a%ple

Air Conditioner -Te%t(I6 E0uipped*

SMCS Code. /20#0+1

i010+53!+

3. Clean the drain plug and install the drain plug*Add the proper oil to the di>>erential* Maintainthe level o> the oil to the &otto% o> the hole>or the di>>erential level->ill plug* Re>er to theOperation and Maintenance Manual@ u&ricant?iscosities and Re>ill Capacities section >or%ore in>or%ation*

Be>ore ;ar% ;eather&egins@ chec. there>rigerant* Alsochec. the re>rigeranti> the air conditionings)ste% does not>unction properl)*

Open the engineco%part%ent*

8hen the outsidete%perature ishigher than 21 C0,@ operate the airconditioning s)ste%>or >ive to ten%inutes*

8hen thes)ste% needsre>rigerant@ see)ourCaterpillardealer >orproperinstallation*

Operate the airconditioner %onthl)

in order tolu&ricatethe co%pressorseals* $et thecontrols onthe%axi%u% setting*Operate the s)ste%>or 1!%inutes*

Close the engineco%part%ent*

4. Clean the >illerplug* 'nstall the>iller plug*

i01225213

A7le OilLeel (Rear* -C)ec2

SMCS Code. /2"0#!/!#,?

A7le Oil(Rear* -C)an8e

i0

12/50+1

'l

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+Maintenance $ection

Air Conditioner # :est

55

g00"!5/2/

SM

lean

the level->illplug* 'nstallthe plug*

'l

g00"!3335

1. Re%ove

thedi>>erenti

aldrainplug*

:heplugisl

o

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3Maintenance

$ectionAxle Oil $a%ple

cateda

tthe&otto%o

>thedi>>eren

tialcase*

9ot

e4raintheo

i

linto

asuita&lecon

tainer*4ispos

eo>theused

oilinanappr

o

priate

%anner*

2. Re%ovethedi>>erentiallevel->illplug*:hedi>>eren

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A7le Oil Sa$ple -O"tain

SMCS Code. /2"0#00+

i01/1"":he &ac.up alar% should start to sound i%%ediatel)*:he &ac.up alar% ;ill continue to sound until thetrans%ission control lever is %oved to the $:O7position or to the ,OR8AR4 position*

'llustration 15!

g00"!3335 'llustration 15 g001002/+

:he drain plug is located on the &otto% o> thedi>>erential*

Re>er to the Caterpillar Machine ,luidsReco%%endations@ $EBU"2!0@ Cooling $)ste%speci>ications and re>er to the Operation andMaintenance Manual@ $a%pling 'nterval andocation o> $a%pling ?alve >or %ore in>or%ation*

'n order to ad6ust the volu%e level@ turn thethree#position selector s;itch* :he s;itch is locatedon the &ac. o> the &ac.up alar%* 8hen the %achineis shipped >ro% the >actor)@ the three#positionselector s;itch is set to the or% the test*

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Appl) the par.ing &ra.e* Move the propel controllever to the RE?ER$E position*

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+1Maintenance

$ectionBelts #

2. :urntheenginestarts;itchtotheO,,position*:urn all s;itches to the O,, position*

'llustration 153g00"11"1

9ote :he &atteries that are supplied ;ith the 'llustration 1!0 g00"5"3+/

%achines are %aintenance >ree &atteries* ou do not need to chec. the level o> the electrol)te in the%aintenance >ree &atteries*

:ighten the &atter) retainers on &oth o> the &atteries*:ighten the &atter) retainers at ever) 1000 hours*

Chec. the >ollo;ing ite%s at ever) 1000 hours* '>necessar)@ chec. the >ollo;ing ite%s %ore o>ten*

F Clean the top o> the &atteries ;ith a clean cloth*

F Clean the &atter) ter%inals* As needed@ coat the&atter) ter%inals ;ith petroleu% 6ell)*

'llustration 1!1 g00"11"1

9atter# -Rec#cle

SMCS Code. 1501#!"1

i00+/"5/! 3. Open the &atter) co%part%ents* :here is oneco%part%ent on each side o> the %achine*

4. At the &atter) disconnect s;itch@ disconnect the

Al;a)s rec)cle a &atter)* 9ever discard a &atter)*

Al;a)s return used &atteries to one o> the >ollo;inglocations

F A &atter) supplier

F An authoriGed &atter) collection >acilit)

F Rec)cling >acilit)

i011321

9atter# or 9atter# Ca"le -Replace

SMCS Code. 1501#!10( 1502#!10

1; :urn the engine start s;itch to the O,, position*:urn all s;itches to the O,, position*

negative &atter) ca&le ;hich is connected tothe >ra%e*

9ote 4o not allo; the disconnected &atter) ca&lesto contact the disconnect s;itch* 4o not allo; thedisconnected &atter) ca&les to contact the otherca&les* 4o not allo; the disconnected &atter)

ca&les to contact the opposite ter%inal o> either&atter)*

5. 4isconnect the negative &atter) ca&le at the&atter)*

6. 4isconnect the negative &atter) ca&le at the&atter)*

7. Re%ove the negative &atter) ca&le >ro% thesecond &atter)* :his ;ill allo; )ou tore%ovethe ca&le*

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8. Re%ove the H &atter) ca&le >ro% the second &atter)* 'n order to re%ove the ca&le thatconnects the t;o &atteries@ )ou %ust re%ove t;ocla%ps* :he t;o cla%ps are located under theradiator at the rear o> the %achine*

9. Re%ove the ca&le >ro% the starter %otor*

10.7er>or% the necessar) repairs* Replace theca&les or the &atteries@ as needed*

11.Reverse the a&ove steps in order to reconnectthe &atteries*

12.Connect the &atter) ca&le at the &atter)disconnect s;itch*

13.'nstall the &atter) disconnect s;itch .e)* :urnthe &atter) disconnect s;itch to the O9 position*

14.'nstall the &atter) co%part%ent covers*

i015/1/"

9elt% - In%pect:Adan drive &elt and ;ith accessor) drive &elts* our engine can also &e eDuipped ;ith analternator &elt* ,or %axi%u% engine per>or%anceand %axi%u% utiliGation o> )our engine@ inspectthe &elts >or ;ear and >or crac.ing* Chec. the &elttension* Ad6ust the &elt tension in order to %ini%iGe&elt slippage* Belt slippage ;ill decrease the &eltli>e* Belt slippage ;ill also cause poor per>or%ance

'llustration 1!2

Open the engine co%part%ent*

Alternator 9elt

'llustration 1!/

g00"500!

g005+55+1

o> the alternator and o> an) driven eDuip%ent*

'> ne; &elts are installed@ rechec. the &eltad6ust%ent a>ter /0 %inutes o> operation* '> t;o &eltsor %ore are reDuired >or an application@ replace the&elts in &elt sets* '> onl) one &elt o> a %atched setis replaced@ the ne; &elt ;ill carr) %ore load* :hisis due to the >act that the older &elts are stretched*:he additional load on the ne; &elt could cause thene; &elt to &rea.*

1. :o chec. the &elt tension@ appl) 110 9 2! l&o> >orce %id;a) &et;een the pulle)s* Correctl)ad6usted &elts ;ill de>lect 1/ to 13 %%1-2 to /-5 inch*

2. 'n order to ad6ust the alternator &elt@ loosen&rac.et &olt 1 and %ounting &olt 2 on thealternator &rac.et*

3. :o achieve the correct ad6ust%ent@ %ove the

alternator in;ard or %ove the alternator out;ard@as reDuired*

4. '> necessar)@ use a pr) &ar in the sDuare hole /in the alternator &rac.et*

5. :ighten %ounting &olt 2 and &rac.et &olt 1*

6. '> ne; &elts are installed@ chec. the &eltad6ust%ent again a>ter /0 %inutes o> engineoperation at the high speed*

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+/Maintenance

$ectionCircuit

7. Chec. the position o> the >an shroud* Ad6ust the position o> the >an shroud so that the >an ;illnot ru& against the shroud* Maintain a 3*5 %%0*/+ inch clearance &et;een the >an and theshroud*

/ater !u$p 9elt

1. :o chec. the &elt tension@ appl) 110 9 2! l&o> >orce %id;a) &et;een the pulle)s* Correctl)ad6usted &elts ;ill de>lect 1/ to 13 %%1-2 to /-5 inch*

'llustration 1!!

1. Re%ove the t;o hand .no&s 1*

g00"5!!2

2. :o re%ove the >ilters@ pull up;ard on the

handle2*

'llustration 1!5g00"1/"0

2. :o ad6ust the ;ater pu%p drive &elt@loosen%ounting &olt 1 and &rac.et &olt/*

3.Move idler pulle) 5 in order to achieve thecorrect ad6ust%ent*

4. '> necessar)@ use a pr) &ar in sDuare hole 2 inthe %ounting &rac.et*

'llustration 1!" g00"5!!+0

5. :ighten %ounting &olt 1 and &rac.et &olt /*

6. '> a ne; &elt is installed@ run the engine at ratedspeed >or thirt) %inutes* Chec. the &olt torDue*Read6ust the &elt@ i> necessar)*

i01/1"!

Ca" Air &ilter - Clean:Replace(I6 E0uipped*

SMCS Code. /52#00( /52#!10

:he ca& air >ilter is located to the le>t o> the seat*

3. Clean the >ilters /@ or replace the >ilters*

4. 'nstall the >ilters in the reverse order o> the a&ovesteps*

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Circuit 9rea2er% -Re%et

SMCS Code. 1520#!23

i01!31!1Circuit &rea.er / is designed to protect thealternator* ,or exa%ple@ i> the &atteries are installed;ith reversed polarit)@ the circuit &rea.er ;ouldprevent the alternator >ro% da%aging the recti>ier*:he circuit &rea.er has a capacit) o> "0 A%p*

Coolin8 S#%te$ Coolant(DEAC* - C)an8e

SMCS Code. 1/!2#!55( 1/3!#055

i0120053

'llustration 1!

g00!"+523

!er%onal inront o> theoperator console* 'n order to re%ove the cover 1@ re%ove the >our scre;s* :here is one scre; ateachcorner o> the cover*

A>ter all o> the repairs are co%pleted@ place thecover over the circuit &rea.ers* 'nstall the >ourscre;s*

Circuit Brea.er-Reset I 7ush in the &uttonin order to reset the circuit &rea.er* '> the

electrical s)ste% is >unctioning properl)@the &utton ;ill re%ain depressed* '> the &uttondoes not re%ain depressed@ chec. the appropriateelectrical circuit* Repair the electrical circuit@ i>necessar)*

to )eater% or t)e en8ine contain )ot coolant or%tea$; An# contact can cau%e %eere "urn%;

Re$oe coolin8 %#%te$ pre%%ure cap %lo=l# toreliee pre%%ure onl# =)en en8ine i% %toppedand coolin8 %#%te$ pre%%ure cap i% coolenou8) totouc) =it) #our "are )and;

Do not atte$pt to ti8)ten )o%e connection%=)en t)e coolant i% )ot t)e )o%e can co$e o66cau%in8"urn%;

Coolin8 S#%te$ Coolant Additie contain% al2ali;Aoid contact =it) %2in and e#e%;

9ote :his procedure pertains to Caterpillar 4ieselEngine Anti>reeGe-Coolant 4EAC onl)* :his doesnot pertain to %achines that are shipped >ro% the>actor) ;ith Extended i>e Coolant EC* :his doesnot pertain to %achines that are %aintained ;ithExtended i>e Coolant EC*

9O:'CE4o not change the coolant until )ou read and under#

stand the %aterial in the Cooling $)ste% $peci>ica#tions section*

'llustration 1!+g00!"+5/0

Circuit &rea.er 2 is designed to protect theelectronic throttle* :he circuit &rea.er has a capacit)o> 1! A%p*

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+!Maintenance

$ectionCooling $)ste% Coolant EC #

9O:'CECare %ust &e ta.en to ensure that >luids arecontained during per>or%ance o> inspection@%aintenance@ test# ing@ ad6usting and repair o> theproduct* Be prepared to

collect the >luid ;ith suita&le containers &e>ore open#ing an) co%part%ent or disasse%&ling an) co%po#nent containing >luids*

Re>er to $pecial 7u&lication@ 9E9=2!00@Caterpillar :ools and $hop 7roducts =uide >ortools and supplies suita&le to collect and contain>luids on Caterpillarproducts*

2. Open the engine co%part%ent*

4ispose o> all >luids according to local regulationsand%andate s * 'llustration 1"0 g00"152"5

'> the coolant is dirt) or i> )ou o&serve an) >oa%ingin the cooling s)ste%@ drain the coolant &e>ore the

reco%%ended interval*

't is i%portant to replace the ther%ostat in orderto avoid an) unexpected >ailure o> the ther%ostat*:his is a good preventive %aintenance practice thatreduces the chances o> unscheduled do;nti%e*,ailure to replace the ther%ostat on a regularl)scheduled &asis could cause severe engineda%age*

9ote '> )ou are onl) replacing the ther%ostat@ drainthe coolant >ro% the cooling s)ste% so that the levelo> the coolant is &elo; the ther%ostat housing*

3. $lo;l) re%ove the cooling s)ste% pressure capin order to relieve pressure*

Al;a)s operate Caterpillar engines ;ith a ther%ostat &ecause these engines have a shunt design coolings)ste%*

'llustration 1"1g00"15253

9ote :her%ostats can &e reused i> the ther%ostats%eet certain test speci>ications* :he testedther%ostats %ust not &e da%aged and the testedther%ostats %ust not have an excessive &uildupo> deposits*

1; $top the engine and allo; the engine to cool*

4. Open the drain valve that is under the radiator*Allo; the coolant to drain into a suita&lecontainer*

5. Close the drain valve* ,ill the cooling s)ste% ;ithclean ;ater and ;ith a " to 10J concentration o>cooling s)ste% cleaner*

6. $tart the engine* Run the engine >or 30 %inutes*

7. $top the engine* 4rain the cleaning solution*

8. ,lush the cooling s)ste% ;ith ;ater until thedraining ;ater is transparent*

9. Close the drain valve*

10.Add the coolant solution* Re>er to Operation andMaintenance Manual@ Re>ill Capacities*

'llustration 1!3 g00"500!

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9ote '> )ou are using Caterpillar ong i>e Coolant that contains so%e additive@ do not add an)supple%ental coolant additive at this ti%e * Also@ donot change the coolant conditioner ele%ent i> )ouare using Caterpillar ong i>e Coolant that containsso%e additive*

11.:a.e o>> the cooling s)ste% pressure cap* $tart the engine and run the engine* eave the cap o>>until the ther%ostat opens and the coolant levelsta&iliGes*

i015/103+

Coolin8 S#%te$ Coolant(ELC*# C)an8e

SMCS Code. 1/3!#055#9

!er%onal inica#tions section*

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9O:'CEExcessive additive greater than the reco%%ended"J initial >ill together ;ith concentrations o>anti>reeGegreater than "0J cause deposits to >or%and can re#

sult in radiator tu&e &loc.age andoverheating*

'llustration 1""

g00"152+0

Use 8T-5296 :est Kit in order to chec. theconcentration*

Li0uid Supple$ental CoolantAdditie

1; $top the engine* Allo; the cooling s)ste% toco%pletel) cool*

11.Maintain the level o> the coolant to the %iddle o> the sight gauge*

12.Replace the cooling s)ste% pressure cap i> thegas.et is da%aged* 'nstall the cooling s)ste%pressure cap*

13.$top the engine*

14.Close the engine co%part%ent*

Coolin8 S#%te$ Coolant

Additie (DEAC* - AddSMCS Code. 1/!2#!55

i01200"!"

'llustration 1"


g00"500!

At operatin8 te$perature t)e en8ine coolant i%)ot and under pre%%ure;

Stea$ can cau%e per%onalinor%ation >or in>or%ation on

Containing ,luid $pillage*

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+3Maintenance

$ectionCooling $)ste% Coolant $a%ple

4. '> necessar)@ drain enough coolant >ro% theradiator in order to allo; the addition o> the liDuidcoolant additive*

5. Add 0*25 iters *!0 pint o> cooling s)ste%additive >or ever) /+ iters 10 U$ =allons o>

engine cooling capacit)*

6. 'nspect the gas.et >or the cooling s)ste%pressure cap* Replace the cap i> the gas.et isda%aged*

7. 'nstall the cooling s)ste% pressure cap*

8. Close the engine co%part%ent*

Use a 8T-5296 Coolant :est Kit to chec. theconcentration o> the coolant*

9O:'CEMixing EC ;ith other products that do not %eetCaterpillar EC#1 speci>ications reduces the e>>ective#ness o> the coolant and shor tens coolant service li>e*

Use onl) Caterpillar products or co%%ercialproducts that have passed the Caterpillar EC#1speci>ication>or pre#%ixed or concentrate coolants*Use onl)Caterpillar Extender ;ith Caterpillar EC*

,ailure to >ollo; these reco%%endations can resultinshortened cooling s)ste% co%ponent li>e*

Coolin8 S#%te$ Coolant

E7tender (ELC* - AddSMCS Code. 1/!2#!55#9

i01200"0 1. $top the engine* Allo; the cooling s)ste% toco%pletel) cool*


Stea$ can cau%e per%onal inluids arecontained

during per>or%ance o> inspection@ %aintenance@test# ing@ ad6usting and repair o> the product* Beprepared tocollect the >luid ;ith suita&le containers&e>ore open#ing an) co%part%ent or disasse%&ling an) co%po#nent containing >luids*

Re>er to $pecial 7u&lication@ 9E9=2!00@Caterpillar :ools and $hop 7roducts =uide >ortools and supplies suita&le to collect and contain>luids on Caterpillar

'llustration 10 g00"152"5

products*

4ispose o> all >luids according to local regulations

and%andates*

8hen a Caterpillar Extended i>e Coolant EC isused@ an Extender %ust &e added to the cooling

s)ste%*

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++Maintenance $ectionCooling $)ste% Coolant Extender EC # Add

3. $lo;l) loosen the cooling s)ste% pressurecapin order to relieve s)ste% pressure*Re%ove thecooling s)ste% pressure cap*

4. '> necessar)@ drain enough coolant >ro%theradiator in order to allo; the addition o>theExtender*

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5. Add the reco%%ended a%ount o> extender to the coolant s)ste%* Re>er to the Caterpillar Machines,luids Reco%%endations@ $EBU"2!0@ Cooling$)ste% $peci>ications >or the proper a%ount*

9O:'CECare %ust &e ta.en to ensure that >luids arecontained during per>or%ance o> inspection@%aintenance@ test# ing@ ad6usting and repair o> theproduct* Be prepared to

collect the >luid ;ith suita&le containers &e>ore open#ing an) co%part%ent or disasse%&ling an) co%po#nent containing >luids*

Re>er to $pecial 7u&lication@ 9E9=2!00@Caterpillar :ools and $hop 7roducts =uide >ortools and supplies suita&le to collect and contain>luids on Caterpillarproducts*

4ispose o> all >luids according to local regulationsand%andates*

'llustration 11

g00"152+01; $top the engine* Allo; the cooling s)ste% to

co%pletel) cool*

6. Maintain the level o> the coolant to the %iddle o>the sight gauge*

7. 'nspect the gas.et on the cooling s)ste%pressure cap* Replace the cooling s)ste%pressure cap i> the gas.et is da%aged*

8. 'nstall the cooling s)ste% pressure cap*


Coolin8 S#%te$ CoolantSa$ple - O"tain

SMCS Code. 1/3!#00+

i01200+5!

'llustration 12


g00"500!


Stea$ can cau%e per%onal

in

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30Maintenance $ectionCooling $)ste% evel # Chec.

i01200++3

Coolin8 S#%te$ Leel - C)ec2

SMCS Code. 1/!0#!/!#,?( 1/3!#!/!#,?


Stea$ can cau%e per%onal in the%achine*

'llustration 1!g00"152+0

8. Maintain the level o> the coolant to the %iddle o>the sight gauge*

9. :ighten the cooling s)ste% pressure cap*


'llustration 1g00"152+0

; Maintain the level o> the coolant in the sightglass* :he sight glass is located near the upperradiator hose*

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i0120030"

Coolin8 S#%te$ !re%%ure Cap# Clean:Replace

SMCS Code. 1/+2#00( 1/+2#!10

!er%onal in

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8. Add the cooling s)ste% coolant* Maintain the level o> the coolant to the %iddle o> the sightglass*

9. 'nspect cooling s)ste% pressure cap and thegas.et >or da%age* Replace the pressure cap i>

the pressure cap or the gas.et are da%aged*

10.'nstall the cooling s)ste% pressure cap*


i012012!/

Cran2%)a6t Vi"ration Da$per# In%pect

'llustration 1+!g00/+00"

SMCS Code. 120!#050

4a%age to the cran.sha>t vi&ration da%per or>ailure o> the cran.sha>t vi&ration da%per canincrease torsional vi&rations* :his can result inda%age to the cran.sha>t and to other engineco%ponents* A deteriorating da%per can causeexcessive gear train noise at varia&le points in thespeed range*

:he da%per is %ounted to the cran.sha>t on the>ront o> the engine*

?isuall) inspect the cran.sha>t vi&ration da%per >orda%age*

'llustration 1+/


g00"500!

Chec. the &olts >or proper tightness* Re>er tothe Operation and Maintenance Manual@:orDue$peci>ications*

Close the engine co%part%ent*

i0113/1"5

Cuttin8 Ed8e% (Leelin8 9lade*# In%pect:Replace

SMCS Code. "+01#050( "+01#!10

!er%onal in

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35Maintenance $ection4ru% Cooling Oil # Change

i012/5!15

Dru$ Coolin8 Oil - C)an8e

SMCS Code. ""0!#055#OC

'llustration 1+"g00"5"0/

:here are t;o cutting edges on the >ront o> the&lade 1* :here are t;o s.id plates on the &otto%o> the &lade 2*

Replace the cutting edge i> the cutting edge is

'llustration 1+g00""02/1

da%aged* Replace the cutting edge i> the cuttingedge is excessivel) ;orn*

1. Raise the leveling &lade* Bloc. the leveling &ladesecurel)* 7lace the &loc.s under the ar%s /o> the &lade*

2. Re%ove the &olts* Re%ove the cutting edge*

3. Clean the contact sur>aces*

4. '> the opposite edge o> the cutting edge is not;orn@ use the opposite edge* '> the oppositeedge is ;orn@ replace the cutting edge*

5. 'nstall the &olts* :ighten the &olts to thetorDues that are speci>ied in the Operationand Maintenance Manual@ :orDues >or=roundEngaging :ool Bolts*

6. 'nspect the s.id plates* Replace the s.id platesi> the s.id plates are da%aged or ;orn*

7. Raise the leveling &lade* Re%ove the &loc.s*

8. o;er the leveling &lade to the ground*

9. Chec. the &olts >or proper torDue a>ter a >e;hours o> operation*

9ote Clean the area around the >ill-drain plug&e>ore servicing the dru%*

:he dru% cooling oil reDuires service ;hen thedisasse%&l) o> the dru% or the asse%&l) o> thedru% is needed*

Rotate the >ill-drain plug to the &otto% o> the dru%*Re%ove the drain plug* 7u%p the oil out o> the dru%*

Use the drain plug opening in order to >ill the cavit)*

'nstall the plug a>ter adding the correct a%ount o>oil* :he oil ;ill &e near the &otto% o> the opening*

'n order to chec. the level o> the oil@ rotate the dru%so the plug is at the &otto% o> the dru%* Re%ove theplug* Maintain the oil to the &otto% o> the opening*

Re>er to the Operation and Maintenance Manual@u&ricant ?iscosities and the Operation andMaintenance Manual@ Re>ill Capacities*

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Dru$ Scraper% -In%pect:Adront o>the dru%* :he second scraper is at the rear o> thedru%*

Adlexi&le scrapers i> the >lexi&lescrapers are excessivel) ;orn or the scrapers

are da%aged*

2. oosen the &olts and the nuts 1 that are holdingthe >lexi&le scraper /*

3. Re%ove the >lexi&le scraper /* 'nstall the ne;>lexi&le scraper*

9ote 8hen )ou ad6ust the scraper /@ the steel&ac.ing plates 2 %ust not co%e into contact ;iththe sur>ace o> the dru%*

4. Ad6ust the >lexi&le scraper &lades 2 to %%0*2! inch a;a) >ro% the sur>ace o> the dru%*

:he &ac.ing plates 2 %ust &e set &ac. /! %%1*/! inch >ro% the end o> the scraper* Ad6ustthe scraper &lades / and the &ac.ing platestogether*

5. :ighten the &olts and tighten the nuts*

Steel Scraper%

:here is one scraper that is located on the >ront&u%per*

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3"Maintenance $ection4ru% $upport Oil # Change

Adro% thedru% sur>ace*

!added Dru$ Scraper A%%e$"l#(I6E0uipped*

Ad thedru%*

'llustration 131

g005+0155

'llustration 13/ g000000

:here is one scraper that is located in >ront o> thedru%*

9ote 8hen the >ill plug 1 is in the t;elve oLcloc.position@ the level chec. plug 2 is in the threeoLcloc. position* :he drain plug / ;ill &e located at the six oLcloc. position*

'llustration 132 g0055//01

:here is an optional scraper that is located at the'llustration 135 g00000+

rear o> the dru%*

1. 'nspect the scraper* Clean the dirt and the de&ris>ro% the scraper*

2. :here are t;o &olts 2 >or each scraper*Eachscraper is individuall) ad6usta&le*

3. $lide the scraper to;ard the dru%* Ad6ust thetips so the tips are 2! %% 1 inch >ro% the sur>ace o> the dru%*

4. :ighten &olts and the nuts*

1. Rotate the dru% until the drain plug / is locatedat the six oLcloc. position*

2. Re%ove the drain plug /* 4rain the oil intoa suita&le container* 4ispose o> the oil in anaccepta&le %anner*

3. A>ter the oil is drained@ clean the drain plug*'nstall the drain plug*

4. :he >ill plug 1 is located at the t;elve oLcloc.position*

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5. Re%ove the >ill plug 1*

6. Re>er to the Operation and Maintenance Manual@u&ricant ?iscosities and Re>ill Capacities*

7. ,ill the support until the oil is at the &otto% o> the

>ill plug opening*

8. Clean the plug* 'nstall the plug*

9. Chec. the level o> oil in the housing* Maintain thelevel o> oil at the level chec. plug 2*

i01/2/5!"

Dru$ Support Oil Sa$ple -O"tain(CS-531D Mac)ine Onl#*

SMCS Code. ""0!#00+

S:N.A=t side o> thedru%*

Dru$ Support Oil -C)ec2(CS-531D Mac)ineOnl#*

SMCS Code. ""0!#!/!#,?

S:N.A=t side o> thedru%*

'llustration 13" g00000"!

Re>er to the Caterpillar Machine ,luidsReco%%endations@ $EBU"2!0@ $O$ Oil Anal)sis*Re>er to the Operation and Maintenance Manual@

$a%pling 'nterval and ocation o> $a%pling ?alve>or in>or%ation on o&taining the oil sa%ple >ro% thedru% support*

9ote A>ter )ou o&tain an oil sa%ple@ add oil in orderto %aintain the proper level*

'llustration 13! g000000i015+105/

9ote 8hen the >ill plug 1 is in the t;elve oLcloc.position@ the level chec. plug 2 is in the threeoLcloc. position* :he drain plug ;ill &e located at the six oLcloc. position*

1. Re%ove the level chec. plug 2* Chec. the levelo> the oil in the housing* Maintain the level o> theoil at the &otto% o> the level chec. plug opening*

2. '> the oil level is lo;@ re%ove the >ill plug 1*

3. Re>er to the Operation and Maintenance Manual@u&ricant ?iscosities and Re>ill Capacities* ,illthe support until the oil is at the &otto% o> thelevel plug opening*

4. Clean >ill plug 1 and install the plug*

Eccentric /ei8)t ,ou%in8 Oil# C)an8e

SMCS Code. ""0"#055#OC

C)an8e t)e Oil

1. :a.e an oil sa%ple >ro% each eccentric ;eighthousing* :here is one eccentric ;eight housingon each side o> the dru%* 9o >lushing isnecessar)@ i> the oil sa%ple cleanliness ratingis eDual or lo;er than '$O 2/-21* :he >lushingprocedure should &e per>or%ed i> an oil sa%plecleanliness rating is higher than '$O 2/-21*

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3+Maintenance $ectionEccentric 8eight the dru%* :he drain plug is at the &otto%o> the housing*

3. 7lace a suita&le container under the drain plug*Re%ove the drain plug* 4rain the housingco%pletel)* Repeat this step >or &oth housings*

4. Clean the plug* 'nstall the plug*

5. Rotate the dru% until the ;elded ite% is at the&otto% o> the dru%*

7. Re%ove the level chec. plug* ,ill the housing;ith oil* Re>er to the Operation and MaintenanceManual@ u&rication ?iscosities and Operationand Maintenance Manual@ Re>ill Capacities*Maintain the level o> the oil to the &otto% o> the level chec. opening*

8. Clean the plugs* 'nstall the plugs*

9. Repeat this procedure >or the other eccentric;eight housing*

&lu%) t)e ,ou%in8

'llustration 13+

6. Re%ove the >iller plug*

g00"125"1

'llustration 200g00""1123

1. :here are t;o eccentric ;eight housings* :hehousings are on each side o> the dru%* 7er>or%the >ollo;ing procedure on each housing*

2. 4rain the oil >ro% the eccentric ;eight housings*

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'llustration 201g005113/3 'llustration 20/ g005113/3

3. 7u%p 1!1 50 U$ gal o> a suita&le h)draulicoil into a 20+ !! U$ gal dru%*

5. Raise the %achine* :he dru% and tires %ustnot &e in contact ;ith the ground or the>loor*$upport the %achine on stands*

'llustration 205g005121/3

'llustration 202

(1) 8C-6875 Connector(2) 8B-5774 Reducer Bushing(3) 9U-6989 ice :ee(7) 127-8781 ,ilter Cart(8) 2*5 % + >t o> 2! %% 1 inch hose(9) 3B-6498 El&o;(10) 3L-7024 $treet El&o;(11) 127-0593 Connector(12) 3B-7728 El&o;(13) 3B-7265 7ipe 9ipple(14) 350 %% / inch o> 2! %% 1 inch

pipe

g00"+5/55

6. $tart the engine* Release the par.ing &ra.e androtate the dru% until the >ill-drain plug is at the top o> the housing* Re%ove the plug* 'nstall thevalve and >itting asse%&l) that is appropriate >or)our %achine*

>; Use the 127-8781 :rans>er Cart =roup in orderto >lush the oil in the 20+ !! U$ gal dru%*,ilter the oil >or /0 %inutes* :he particle count o>the clean oil %ust &e a %axi%u% o> '$O 1+-1/*

'llustration 20!g00"3+"/

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100Maintenance $ectionEccentric 8eight the 5R-3796 uic. Coupling

Asse%&l) 1"* 'nstall the adapter into the hole>or the oil >ill-drain plug* Asse%&le the 8T-0198$eal Connector 1! onto the >e%ale end o> theDuic. coupler* Attach the >e%ale end o> the Duic.

coupler to the trans>er cart suction hose in orderto drain the >lushing oil >ro% the housing*

'llustration 20+

10.Run the >irst >lush c)cle*

a. $tarttheengine*Release the&ra.e*

g00"03"15

'llustration 20"

g00""1111

b. $et the travel speed control to lo; speed* 'norder to rotate the dru%@ %ove the propel control*

8. Rotate the dru% until the >ill-drain plug is at the&otto%* 7ut a %ar. on the sur>ace o> the dru% atthe top o> the dru%* :he %ar. ;ill help identi>)the position o> the >ill-drain plug*

a. $et the vi&rator) a%plitude control to the lo;position*

b. :urn on the vi&rator) s)ste%* Run thevi&rator)s)ste% >or ! seconds* :urn o>> thevi&rator)s)ste%* Repeat the c)cle >or three%inutes*

9ote ,or each c)cle@ do not run the vi&rator)

s)ste% %ore than ! seconds*

c. $top the dru%* 7osition the dru% in order todrain the housings*

11.'nstall the trans>er cart* 7u%p the oil out o> thehousings* C)cle the oil through the >ilter >or /0%inutes* C)cle the oil until the oil is cleaned toa rating o> '$O 1+-1/ or &etter*

'llustration 20g005121/3 12.'nstall the trans>er cart to the housings* 7u%p

the oil into the housings* ,or the second c)cle@repeat steps " through 3* A>ter the second c)cle@

?; Re%ove the level chec. plug* Connect the Duic.

coupler 1"* ,ill the housing ;ith 22 " U$ galgallons o> clean oil* 'nstall the plug*

ta.e an oil sa%ple &e>ore >iltering the oil* 9o

>urther >lushing is necessar)@ i> the oil sa%plecleanliness rating is eDual or lo;er than '$O13-1"* Another >lushing is necessar)@ i> the oilsa%ple cleanliness rating is higher than '$O13-1"*

13.8hen the >lushing is co%plete@ rotate the dru%to the position in order to drain the housings*Re%ove the valve and >itting asse%&l)* 4rain as%uch o> the oil as possi&le*

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14.Rotate the dru% until the >ill-drain plug is atthe top* Re%ove the level chec. plug* ,ill thedru% to the correct level* Re>er to the Operationand Maintenance Manual@ Capacities Re>ill* Re>er to the $pecial 7u&lication@ $EBU"2!0@u&rication $peci>ications*

9ote :he ne; oil %ust have a oil sa%plecleanliness rating that is eDual or lo;er than '$O1+-1/*

i0120!333

En8ine Air &ilter !ri$ar#Ele$ent - Clean:Replace

SMCS Code. 10!5#00#7( 10!5#!10#7

9O:'CE4o not clean the >ilter ele%ents &) &u%ping ortapping the%* 4o not use >ilter ele%ents ;ithda%aged pleats@ gas.ets or seals* Engine da%agecan result*

Ma.e sure the cleaned >ilter ele%ents areco%pletel) dr) &e>ore installing into the >ilterhousing* 8ater re# %aining in the ele%ents cancause >alse indications o> conta%ination in$cheduled Oil $a%pling test results*

:he ele%ent can &e ;ashed in a solution thatconsists o> ;ar% ;ater and o> nonsudsinghousehold detergent* ,ull) rinse the pleats* Allo;the >ilter to air dr) co%pletel)*

2. 'nspect the >ilter ele%ents a>ter )ou clean the>ilter ele%ents* 4o not use a >ilter i> the pleats@the gas.ets or the seals are da%aged*

3. Cover the clean >ilter ele%ents* $tore theele%ents in a clean@ dr) location*

Replace the pri%ar) ele%ent a>ter the pri%ar)ele%ent has &een cleaned six ti%es* Alsoreplace the pri%ar) ele%ent i> the pri%ar)ele%ent has &een in service >or one )ear*

Re$oe t)e !ri$ar# Ele$ent

:he >ilter ele%ents can &e cleaned &) using the>ollo;ing %ethods

F pressure air

F pressure ;ater

F detergent ;ashing

8hen )ou use pressure air@ the %axi%u% airpressure is 20! .7a /0 psi* 8hen )ou usepressure ;ater@ the %axi%u% ;ater pressureis2+0 .7a 50 psi*

'llustration 210


g00"500!

'llustration 211

2. Open the air >ilter housing*

g000125+

'llustration 203g000/+"0+

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1; 8hen )ou clean the inside pleats and the outsidepleats@ direct the air along the pleats or directthe ;ater along the pleats*

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9. Reset the >ilter ele%ent indicator*


En8ine Air &ilter SericeIndicator - In%pect

SMCS Code. 5!2#050

i0120"105

'llustration 21g00012!

5. Cover the air inlet opening* Clean the inside o>the air cleaner housing*

'llustration 220 g00"53!/

1. Open the engine co%part%ent access door*

2. $tart the engine*

'llustration 21+

g00012"3. Run the engine at high idle*

6. 'nspect the gas.et &et;een the air inlet pipe andthe air cleaner housing* Replace the gas.et i>the gas.et is da%aged*

7. Uncover the air inlet opening* 'nstall a ne;secondar) ele%ent*

8. 'nstall the pri%ar) ele%ent and the air cleanerhousing cover*

'llustration 221 g00"15!5

4. '> the )ello; piston in the engine air >ilter serviceindicator enters the red Gone@ service the aircleaner*

5. $top the engine*

'llustration 213

g00"155!1

9ote $ee the Operation and Maintenance Manual@Engine Air ,ilter 7ri%ar) Ele%ent # Clean-Replace*$ee the Operation and Maintenance Manual@Engine Air ,ilter $econdar) Ele%ent # Replace*

6. Close the engine co%part%ent access door*

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4. 'nspect the engine %ounts >or correct &olt torDue*

5. :ighten the %ounts i> the %ounts are loose*

3. Re%ove the dipstic. 1* 8ipe the dipstic. ;itha clean cloth* 'nsert the dipstic.* Re%ove thedipstic. and note the oil level* 'nsert the dipstic.*

9ote Re>er to the Operation and MaintenanceManual@ u&ricant ?iscosities and Re>ill Capacities>or the correct a%ount o> oil that is used ;hen the oil is changed* :he correct a%ount o> oil deter%inesthe correct level o> the oil in the ,U range on thedipstic.*

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Caterpillar reco%%ends using the sa%pling valvei> eDuipped in order to o&tain oil sa%ples* :heDualit) and the consistenc) o> the sa%ples is &etter;hen the sa%pling valve is used* '> the engine is

5; Close the engine co%part%ent*

i0120"!!

not eDuipped ;ith a sa%pling valve@ the use o> a1U-5718 ?acuu% 7u%p is pre>erred*

:o avoid conta%ination o> the oil sa%ples@ thetoolsand the supplies that are used >or o&tainingoilsa%ples %ust &e clean*

Re>er to Caterpillar Machine ,luidsReco%%endations@ $EBU"2!0@ u&ricant$peci>ications >or %ore in>or%ation on o&taining agood oil sa%ple* Consult )our Caterpillar dealer >orco%plete in>or%ation and assistance in esta&lishingan $O$ progra% >or )our engine*

En8ine Oil and &ilter - C)an8e

SMCS Code. 1/1+#!10

Run the engine in order to ;ar% up the oil* $top the engine &e>ore )ou drain the oil* 8hen the oilis ;ar% the ;aste particles are suspended in theoil* :he ;aste particles ;ill &e re%oved ;hen theoil is drained*

As the oil cools@ the ;aste particles settle to the&otto% o> the oil pan* :he ;aste particles ;ill not&e re%oved i> the oil is too cool*

:he ;aste particles can recirculate through theengine lu&rication s)ste% i> the reco%%ended

procedure is not >ollo;ed*

'llustration 2//


g00"500!

'llustration 2/!

1. Open theengineco%part%ent*

g00"500!

'llustration 2/5g00012

2. :he oil sa%pling valve is on the right side o> theengine* :he oil sa%pling valve is located near the steering pu%p* 'llustration 2/" g00012+

3. Open the sa%pling valve* O&tain an oil sa%plein a suita&le container and close the sa%plingvalve*

4. $eal the container and la&el the container* $endthe sa%ple to )our Caterpillar dealer >or anal)sis*

2. 7lace a suita&le container under the drain valve*Open the drain valve*

3. Allo; the oil to co%pletel) drain*

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i011312!"

En8ine Vale La%) andInor the correct procedures ;hen)ou chec. engine valve lash and-or in6ector ,uel:i%ing*

:he ;ater pu%p is located on the engine &loc. atthe >ront o> the engine*

9ote Ma.e sure that Duali>ied service personnelchec. the in6ector ,uel :i%ing* '> an ad6ust%entis necessar)@ %a.e sure that Duali>ied servicepersonnel ad6ust the in6ector ,uel :i%ing* $pecialtools and training are reDuired*

'llustration 252g00012+0

9ote :he correct ,uel :i%ing speci>ication issho;n on the Engine 'n>or%ation 7late* ,uel ti%ingspeci>ications ;ill &e di>>erent ;ith each engineapplication and ;ith each po;er rating*

Consult )our Caterpillar dealer >or the co%pletead6ust%ent procedure*

i0120""35

En8ine /ater !u$p - In%pect

SMCS Code. 1/"1#050

A ;ater pu%p that has >ailed %ight cause severeengine overheating* $evere engine overheatingcould result in the >ollo;ing pro&le%s

F Crac.s in the c)linder head

F 7iston seiGure

F Other potential engine da%age

?isuall) inspect the ;ater pu%p >or lea.s* '> lea.sare >ound@ all the seals %ust &e replaced*

9ote $ee the $ervice Manual@ KE9R/!20 >or %orein>or%ation*

Close the engine co%part%ent*

i01/2/12+

Et)er Startin8 Aid C#linder -Replace

SMCS Code. 15!"#!10#C4

1. Open the engine co%part%ent on the le>t side o>the %achine*

'llustration 25/g00"33311

'llustration 251


g00"500!

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110Maintenance $ection,inal 4rive 7lanetar) Axle Oil # Change

i015+5015

&inal Drie !lanetar# (A7le* Oil- C)an8e

SMCS Code. 50!0#055#OC

'llustration 255g00101/21

2. oosen the c)linder retaining cla%p* Unscre;the e%pt) ether starting aid c)linder and re%ovethe e%pt) ether starting aid c)linder*

'llustration 25"

:his photo ;as ta.en >ro% &elo; the %achine*

1. Re%ovedrainplug2*

2. 4rain theoilintoasuita&lecontainer*

g00212"

3. Cleanthedrainplug@andinstallthedrainplug*

4. Re%ove levelchec.->illplug1*

'llustration 25!

g00105+++5. Add oil to the planetar)* ,ill the planetar) to

the&otto% o> the level chec.->ill plug opening*

6. Re>er to the Operation and Maintenance Manual@

3. Re%ove the used gas.et* 'nstall the ne; gas.etthat is provided ;ith each ne; ether starting aidc)linder*

4. 'nstall the ne; ether starting aid c)linder* :ightenthe ether starting aid c)linder &) hand* :ightenthe c)linder retaining cla%p securel)*


Capacities Re>ill@ and u&rication ?iscosities*

; Clean the level chec.->ill plug and install the levelchec.->ill plug*

9ote :he oil in the >inal drive planetar) is co%%onto the oil in the axle* :he oil in the >inal drive planetar) and the axle should &e drained andre>illed separatel)*

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112Maintenance $ection,inal 4rive 7lanetar) 4ru% Oil # Chec.

8. Clean the plugs 1 and 2* 'nstall the plugs 1and 2*

i015/1133

&inal Drie !lanetar# (Dru$*Oil - C)ec2(CS:C!-533D Mac)ine% Onl#*

SMCS Code. 50!0#!/!#,?( !"!!#!/!#,?

S:N.A,C1#Up

S:N.AE:1#Up

i015/1213

&inal Drie !lanetar# (Dru$*Oil Sa$ple - O"tain(CS:C!-533D Mac)ine% Onl#*

SMCS Code. 50!0#00+( !"!!#00+

S:N.A,C1#Up

S:N.AE:1#Up

'llustration 2!2 g00""02/

'llustration 2!0

g00"5"301O&tain the oil sa%ple according to the Operationand Maintenance Manual@ Maintenance 'nterval$chedule*

:he >inal drive planetar) is located on the le>t side

o> the dru%*

Re>er to the $pecial 7u&lication@ $EBU"2!0@$O$ Oil Anal)sis and re>er to the Operationand Maintenance Manual@ $a%pling 'nterval andocation o> $a%pling ?alve >or %ore in>or%ation*

&uel S#%te$ - !ri$e

SMCS Code. 12!0#!5+

i0120"+1

'llustration 2!1g00"121"1

1. 7lug 2 is located at the 30 degree position*

2. Re%ove the level chec. plug 2* Chec. the levelo> the oil in the gear&ox* Maintain the level o> theoil at the &otto% o> the level chec. plug opening*

3. '> the oil level is lo;@ re%ove the >ill-drain plug 1*

4. 'n order to %aintain the proper oil level@ add oil*

5. Clean the plugs and install the plugs*

'llustration2!/

1. Openthe

engin

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11/Maintenance

$ection,uel $)ste% 7ri%ar) ,ilter #

e co%part%ent* g00"500!

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i01"0013

&uel S#%te$ !ri$ar# &ilter -Clean:In%pect:Replace

SMCS Code. 12"0#050( 12"0#00( 12"0#!10

'llustration 2!5 g005+0/5/

'llustration 2!"

1. Open theengineco%part%ent*

g00"500!

'llustration 2!! g0051+/+

2. Open the valve 1* 7ush the plunger 2 until the>uel starts to co%e out o> the valve*

3. Close the valve 1*

4. 7ush the plunger 2 >or 10 additional stro.es*

5. $tart the engine* Chec. >or lea.s*

'llustration 2!g00"15"3


9ote '> the engine idle is rough@ continue pushingplunger 2 until the engine idle is s%ooth*

2. :urn valve 1 in a countercloc.;ise direction*4rain the >uel into a suita&le container*

9ote 4ispose o> the ;aste in a proper %anner*

3. Close valve 1*4.

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11!Maintenance

$ection,uel $)ste% $econdar) ,ilter #

i01202+/

&uel S#%te$ Secondar# &ilter -Replace

SMCS Code. 12"1#!10#$E

!er%onal inill >uel >ilters ;ith >uel &e>ore installing the%*

Conta%inated >uel ;ill cause accelerated ;ear to>uels)ste% parts*

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9ote Ma.e sure that the drain valves are opened inthe proper order* '> )ou open the ;rong drain valve>irst@ an air loc. in the >uel s)ste% %a) occur* :his ;ill not allo; >uel to drain >ro% the upper secondar)>ilter ele%ent*

3. Re%ove upper secondar) >ilter ele%ent 1*

4. Clean the >ilter %ounting &ase* Ma.e sure thatthe old seal is re%oved*

'llustration 2!3

1; Open the engine co%part%ent*

'llustration 2"0

g00"500!

g005+0/55

5. Coat the seal o> the ne; >ilter ;ith clean diesel>uel*

9ote :he upper secondar) >uel >ilter ele%entand the lo;er secondar) >uel >ilter ele%ent aredi>>erent part nu%&ers* Re>er to the Operation andMaintenance Manual@ Maintenance 7arts ist*

6. 'nstall ne; upper secondar) >ilter ele%ent 1*

ilter ele%ent*8hen the seal contacts the &ase@ tighten theupper secondar) >ilter ele%ent >or an additional/-5 turn*

Rotation index %ar.s are positioned on the >ilterat 30 degree intervals* Use these rotation index%ar.s as a guide ;hen )ou tighten the >ilter*

9ote 'nstall a ne;@ dr) >ilter* 9ever >ill a ne; >ilter;ith >uel &e>ore )ou install the >ilter* 4irt) >uel canda%age the >uel in6ectors* :his da%age ;ill causepre%ature pro&le%s in the >uel s)ste%*

9ote :his %achine is eDuipped ;ith t;o secondar)spin#on >ilters on a single >ilter &ase* :he uppersecondar) >ilter ele%ent is upside#do;n* Al;a)sdrain the inverted secondar) >ilter ele%ent &e>ore)ou re%ove the lo;er secondar) >ilter ele%entor &e>ore )ou re%ove the upper secondar) >ilterele%ent*

; 4rain upper secondar) >ilter ele%ent 1 inverted>ilter* 7lace a suita&le container under the drainvalves 2 and 5* Open drain valve 2 >irst*:hen@ i%%ediatel) open drain valve 5* 4rainthe >uel into a suita&le container* 8hen the >uel

stops draining@ .eep the drain valves open*oosen the inverted secondar) >ilter ele%ent>or 1-5 turn* As the secondar) >ilter ele%ent isloosened@ additional >uel %a) drain >ro% the drainvalves* 8hen the >uel stops draining@ loosen thesecondar) >ilter ele%ent >or an additional 1-5turn* O&serve the >lo; o> the >uel* Repeat thisprocedure until >uel does not drain >ro% thedrainvalves* Close the drain valves* 7roperl)disposeo> the >uel*

7. Re%ove lo;er secondar) >ilter ele%ent /*

9ote o;er secondar) >ilter ele%ent / has not&een drained* :he >ilter contains >uel* 8hen )oure%ove the lo;er >ilter@ use caution in order to avoidspilling the >uel*

8. Clean the >ilter %ounting &ase* Ma.e sure thatthe old seal is re%oved*

9. Coat the seal o> the ne; >ilter ;ith clean diesel>uel*

10.'nstall ne; lo;er secondar) >ilter ele%ent /*ilter ele%ent*8hen the seal contacts the &ase@ tighten thelo;er secondar) >ilter ele%ent >or an additional/-5 turn*

9ote 'nstall a ne;@ dr) >ilter* 9ever >ill a ne; >ilter;ith >uel &e>ore )ou install the >ilter* 4irt) >uel canda%age the >uel in6ectors* :his da%age ;ill causepre%ature pro&le%s in the >uel s)ste%*

11.7ri%e the >uel s)ste%* $ee the Operation andMaintenance Manual@ ,uel $)ste% # 7ri%e*

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11Maintenance

$ection,uel :an. Breather #

12.$tart the engine and chec. >or lea.s*


i0120/0!

i0120/1+

&uel S#%te$ /ater SeparatorEle$ent - Replace(&uel S#%te$ !ri$ar# &ilter

&uel S#%te$ /aterSeparator# Drain

SMCS Code. 12"/#!5/

Ele$ent*SMCS Code. 12"/#!10#,

'llustration 2"1


g00"500!

'llustration 2"/


g00"500!

'llustration 2"5 g00"15"3

'llustration 2"2g00"15"3 2. :urn the valve 1 in a countercloc.;ise direction*

2. 'n order to open the drain valve 1@ turn thevalve in a countercloc.;ise direction* Allo; the;ater to co%pletel) drain*

3. 4rain the ;ater and sedi%ent into a suita&lecontainer*


4. Close the drain valve 1*


4rain the >uel into a suita&le container*


3. Close the valve 1*

4.

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i0120502

&uel Tan2 9reat)er - Replace

SMCS Code. 12/#!10#BRE

'llustration 2""


g00"5"!!3

'llustration 2"!g00/2+/!

5. oosen the collar 2* Re%ove the ele%ent /*4iscard the ele%ent in a proper %anner*

6. Clean the parts* 'nspect the parts >or da%age*Replace the da%aged parts or replace the ;ornparts*

7. 'nstall a ne; ele%ent* :ighten the collar 2* 'llustration 2" g00"1511

8. 'nstall the &o;l ! and tighten the collar 5*

9. $tart the engine and chec. the >uel s)ste% >orlea.s*


2. :he >uel tan. &reather is located &ehind the >ueltan. cap* Re%ove the &reather*

3. 'nstall the ne; &reather*


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113Maintenance

$ection,uses #

i0120503

&uel Tan2 Cap and Strainer -Clean

SMCS Code. 12/#00#N2( 12/#00#$:R

4. 8ash >iller screen 2 in clean@ non>la%%a&lesolvent* 4r) the >iller screen ;ith pressureair*

5. 'nspect cap 1 and >iller screen 2* Replacethe cap i> the cap is da%aged* Replace the >iller

screen i> the >iller screen is da%aged*

6. 'nstall >iller screen 2*

7. Appl) a thin >il% o> >uel to the gas.et o> the >ueltan. cap*

8. 'nstall >uel tan. cap 1*


'llustration 2"+


g00"500!

i01205/!

&uel Tan2 /ater and Sedi$ent# Drain

SMCS Code. 12/#!5/#MP$

'llustration 2"3

2. Re%ove >uel tan. cap 1*

g00"15+1"

'llustration 21

:his is the location o> the >uel tan.*

g00"5+/0

'llustration 20

3. Re%ove>illerscre

en

2*

g00"15+1!

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11+Maintenance $ection,uel :an. Cap and $trainer # Clean

'llustration 22 1. Re%ove the access plate* g00"12"5

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'llustration 2/g00"12+2" 'llustration 2! g00"1!02

2. :he drain valve is located on the &otto% o> the>uel tan.* 4rain the ;ater and the sedi%ent intoa suita&le container*

3. Close the drain valve* 'nstall the access plate*

9ote 4ispose o> all >luids according to localregulations*

1I4o%eight

(2)I Co%paction Meter

(3)I 'gnition $)ste%

&u%e% - Replace

SMCS Code. 151#!10

i011!"3"! (4)I uses protect the electricals)ste% >ro% da%age that is caused &)overloaded circuits* Change the >use i> the

ele%ent separates* '> the ele%ent o> the ne; >useseparates@ chec. the circuit* Repair the pro&le%&e>ore )ou operate the %achine*

'llustration 2"g00"1!!1"

(5)I :her%al $tarting Aid

'llustration 25g00"1!!/!

(6)I Bac.up Alar%

:he co%part%ent >or the >uses is located on theright side o> the %achine* :here are >our scre;s thathold the cover on the co%part%ent*

'n order to access the co%part%ent >or the >uses@re%ove the >our scre;s* Re%ove the cover*

I ,ront 8or. ights

+ I =auge ights

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120Maintenance $ection

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'llustration 2+1g00"1!205 'llustration 2+/ g00"1!1"

5. Connect a hose to the h)draulic oil tan. drainvalve* :he drain valve is located on the &otto%o> the h)draulic oil tan.*

9ote :he h)draulic oil tan. contains +0 21*1 U$ gal o> h)draulic oil* 4rain the oil into asuita&le container* 4ispose o> the used oil in aproper %anner*

6. Close the h)draulic oil tan. drain valve* Re%ovethe hose*

1; Maintain the oil level at the level %ar. on the decal* :he decal is &eside the sight gauge*

i01205/!3

,#draulic S#%te$ Oil &ilter -Replace

SMCS Code. !0"+#!10

'llustration 2+5g00"5+/21

'llustration 2+2

7. 4isconnect the t;o hoses*

g00012+/

8. Re%ove the t;o strainers* Clean the strainers in

a non>la%%a&le solvent* 4r) the strainers ;ithpressure air*

9. 'nstall the t;o strainers*

10.Re>ill the h)draulic tan. ;ith clean@ >ilteredh)draulic oil* Re>er to the Operation andMaintenance Manual@ Re>ill Capacities andu&ricant ?iscosities*

11.Add the oil through the >iller tu&e* Clean the capand install the cap*

'llustration 2+!


g00"5+//1

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122Maintenance $ectionilters* :here is one >ilter on theright side o> the %achine@ and there is one >ilteron the le>t side o> the %achine* :he >ilters are located near the >ront o> the %achine* :he >iltersare located &ehind the >ra%e* :he propel >ilter 1is on the right side o> the %achine* :he vi&rator)

>ilter 2 is on the le>t side o> the %achine*

3. 'n order to catch an) oil that spills@ place asuita&le container under the >ilters*

4. Re%ove the t;o >ilter ele%ents* Clean the >ilter&ases* 4iscard the >ilters in a proper %anner*

5. Coat the gas.et o> ne; >ilters ;ith clean oil*

i01205515

,#draulic S#%te$ Oil Leel -C)ec2

SMCS Code. !0!"#!/!#,?( !03!#!/!#,?

6. 'nstall the ne; >ilter ele%ents* ilter&ase@ turn the >ilter ele%ent >or an additional

three Duarters o> a turn* :his ;ill tighten the >iltersu>>icientl)*

Rotation index %ar.s are positioned on the >ilterat 30 degree intervals* Use these rotation index%ar.s as a guide ;hen )ou tighten the >ilter*

'llustration 2+


g00"500!

'llustration 2+"

g00"1!1" 'llustration 2++ g00"1!1"

7. $tart the engine* Allo; the h)draulic oil to ;ar%*Maintain the oil to the level %ar. on the decalthat is near the sight gauge* '> necessar)@ add

oil*

Re>er to the Operation and Maintenance Manual@Re>ill Capacities* Re>er to the Operation andMaintenance Manual@ u&ricant ?iscosities*


2. O&serve the level o> the h)draulic oil in the sightgauge ;hen the oil is ;ar%* Maintain the oil levelto the %ar. on the sight gauge*

3. '> necessar)@ add oil*

Re>er to the Operation and Maintenance Manual@Re>ill Capacities* Re>er to the Operation andMaintenance Manual@ u&ricant ?iscosities**

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i012050/2

,#draulic Tan2 Strainer - Clean

SMCS Code. !0!"#00#$:R

'llustration 2+3g00"1!103

4. 'n order to add the oil@ re%ove the >iller cap 1*Add the oil through the >iller tu&e* Clean the oil>iller cap and install the >iller cap*


i015!0++/

,#draulic S#%te$ Oil Sa$ple# O"tain

SMCS Code. !0!0#00+( !03!#00+

'llustration 231


g00"500!

'llustration 232g00"1!103

'llustration 230 g00"!3!21

:he port is located &ehind the >ra%e near the propel >ilter*

Re>er to the $pecial 7u&lication@ $EBU"2!0@$O$ Oil Anal)sis and re>er to the Operationand Maintenance Manual@ $a%pling 'nterval andocation o> $a%pling ?alve >or %ore in>or%ation*

'llustration 23/g00"1!121

2. Re%ove the h)draulic oil >iller cap 1 and pullthe screen 2 out;ard*

3. Clean the screen in clean@ non>la%%a&le solvent*4r) the screen ;ith pressure air*

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125Maintenance $ection

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'llustration /00g00"5"200

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12Maintenance

$ectionRollover 7rotective $tructure RO7$

3. '> the engine starts &e>ore )ou %ove the propellever to the $:O7 position@ the neutral starts;itch reDuires ad6ust%ent* 4o not operate the%achine until the repairs have &een %ade*Consult )our Caterpillar dealer >or instructions*

Using an oil >ilter ele%ent that is not reco%%ended&) Caterpillar can result in severe engine da%age to engine &earings@ to the cran.sha>t@ and to otherparts* :his can result in larger particles in un>ilteredoil* :he particles could enter the lu&ricating s)ste% and the particles could cause da%age*

Oil &ilter - In%pecti01531"3

Radiator Core - Cleani011+"10

SMCS Code. 1/0+#!0( /005#!0( /0"#!0(!0"+#!0

In%pect A '%ed &ilter 6orDe"ri%

SMCS Code. 1/!/#00#KO

'llustration /0/

g0010001/

'llustration /05


g00"500!

:he ele%ent is sho;n ;ith de&ris*

Use a 4C-5084 ,ilter Cutter or a 175-7546 Oil,ilter Cutter to cut the >ilter ele%ent open* $pread apart the pleats and inspect the ele%ent >or %etal and >or other de&ris* An excessive a%ount o> de&risin the >ilter ele%ent can indicate a possi&le >ailure*

'> %etals are >ound in the >ilter ele%ent@ a %agnetcan &e used to di>>erentiate &et;een >errous %etalsand non>errous %etals*

,errous %etals can indicate ;ear on steel parts andon cast iron parts*

9on>errous %etals can indicate ;ear on thealu%inu% parts o> the engine such as %ain&earings@ rod &earings@ or tur&ocharger &earings*

$%all a%ounts o> de&ris %a) &e >ound in the >ilterele%ent* :his could &e caused &) >riction and &)nor%al ;ear* Consult )our Caterpillar dealer inorder to arrange >or >urther anal)sis i> an excessivea%ount o> de&ris is >ound*

2. :he radiator core is located at the rear o> the%achine*

3. 'nspect the radiator core >or de&ris* '> necessar)@clean the radiator*

Co%pressed air is pre>erred@ &ut high pressure;ater o> stea% can &e used to re%ove dust andgeneral de&ris >ro% a radiator* Clean theradiatoraccording to the condition o> theradiator*

$ee $pecial 7u&lication@ $EB40!1+@ Kno; ourCooling $)ste% >or %ore in>or%ation a&outcleaning radiator >ins*


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i011+"0

Rolloer !rotectieStructure(RO!S* - In%pect

SMCS Code. /2/#050( /2!#050

Al;a)s chec. the condition o> the seat &elt* Al;a)schec. the condition o> the %ounting hard;are*:he chec.s %ust &e done &e>ore )ou operate the%achine*

ou %ust replace the seat &elt once during a three

)ear period* :he &elt %ust &e replaced regardlesso> an) da%age* A date la&el is attached to the &elt*:he date la&el ;ill deter%ine the age o> the &elt*

'nspect the &elt >or ;orn ;e&&ing or >or >ra)ed ;e&&ing*

Chec. >or ;orn &uc.les on each hal> o> the seat &elt* Chec. >or da%aged &uc.les on each hal> o>the seat &elt* Replace the seat &elt or replace the &uc.les i> the &elt or the &uc.les are da%aged*

'llustration /0! g00"5+"1"

'nspect the rollover protective structure RO7$ >oran) loose &olts or da%aged &olts* Replace theda%aged &olts ;ith original eDuip%ent parts onl)*

Replace the RO7$ %ounting support i> the RO7$rattles* Replace the RO7$ %ounting support i> theRO7$ %a.es noise*

4o not straighten the RO7$ or repair the RO7$ &);elding rein>orce%ent plates to the RO7$*

'llustration /0 g00"5"0++

Consult )our Caterpillar dealer >or the repair o> theRO7$*

'nspect the &elt %ounting hard;are* Replace an);orn hard;are or da%aged hard;are* Keep the%ounting &olts tight*

Seat 9elt - Replace

SMCS Code. /2#!10( /2

i015/1/!+

Steerin8 C#linder End% -Lu"ricate

SMCS Code. 5/0/#0+"#B4

i011+"053

'llustration /0"g00"5!/2!

'llustration /0+g00"0"+5+

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123Maintenance

$ection:ire 'n>lation

o;er the steering >ra%e loc. pin into the loc.ed position*

9ote 8ipe all o> the >ittings &e>ore )ou lu&ricatethe >ittings*

'llustration /11g00"!0"0/

'llustration /03

g00"123!5

1. Raise the engine hood* :he tilt hood actuator islocated on the right side o> the %achine*

2.,ull) extend the c)linder and grease the innerpost 2* =rease the entire length o> the inner

1; :here are t;o steering c)linders@ one on the right post*side o> the %achine and one on the le>t side o> the %achine* u&ricate the >ront lu&e >itting 1on each side o> the %achine*

'llustration /12g00"!0"03

'llustration /10

g00"123+"

3. u&ricate the t;o >ittings / on the c)linder*

4. Close the engine hood*

2. Both the lu&rication >ittings >or the rear end o> thesteering c)linders are located on the le>t side o>the %achine* u&ricate the >ittings 2 >or the rearend o> the steering c)linders*

3. Raise the steering >ra%e loc. pin into theunloc.ed position*

i011+"00+

Tilt ,ood Actuator - Lu"ricate

SMCS Code. 2!1#0+"#A

8ipe all the grease >ittings &e>ore lu&ricating*

Lu"ricate T)e ,ood

'llustration /1/ g00"1!/22

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:here are t;o lu&rication points >or the hood* Onelu&rication point is on the right side o> the hood andone lu&rication point is on the le>t side o> the hood*

u&ricate &oth sides o> the hood*

i0120532

Vi"rator# Support Oil - C)an8e

SMCS Code. !"!"#055#OC

Tire In6lation - C)ec2

SMCS Code. 520/#!/!#7Q

i011+!3"/

'llustration /1!g00"5+""!

:he vi&rator) drive gear&ox is located on the rightside o> the dru%*

'llustration /15

'> necessar)@ in>late thetires*

g00"5+""/

,or nor%al operating conditions@ in>late the tires tothe proper pressure

F :he proper pressure >or the C$#!/14 is 110 .7a1" psi*

F :he proper pressure >or the C$#!//4 is 110 .7a1" psi*

F :he proper pressure >or the C7#!//4 is +/ .7a'llustration /1" g005+55+

12 psi*

:he tire in>lation pressure is &ased on the ;eight o>a %achine that is read) to ;or. and the %achine is;ithout attach%ents* :he pressure is &ased on therated pa)load@ and in average operating conditions*

7ressures >or each application %a) var)* Consult)our Caterpillar dealer >or %ore in>or%ation a&outproper tire in>lation pressures*

1. Re%ove the drain plug /* 4rain the oil into asuita&le container*

9ote 4ispose o> the used oil in a proper %anner*

2. Clean the drain plug / and install the drainplug*

3. Re%ove the oil level chec. plug 2*

4. Re%ove the oil >iller plug 1*

5. Add the oil through the oil >iller plug hole 1*Add the oil until the oil reaches the &otto% o> theopening >or the oil level chec. plug*

6. Re>er to the Operation and Maintenance Manual@u&ricant ?iscosities and Re>ill Capacities*

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1/1Maintenance

$ection8heel 9uts #

7. Clean the oil level chec. plug and install the oillevel chec. plug* Clean the >iller plug and installthe >iller plug*

i0120!10

i0120!"!

Vi"rator# Support Oil Sa$ple# O"tain

SMCS Code. !"!"#00+

Vi"rator# Support Oil Leel - C)ec2

SMCS Code. !"!"#!/!#,?

'llustration /13g00"5+""!

'llustration /1

g00"5+""!

O&tain the oil sa%ple ;hen )ou change the oil*

Re>er to the Caterpillar Machine ,luidsReco%%endations@ $EBU"2!0@ u&ricant$peci>ications* Re>er to the Operation and

:he vi&rator) drive gear&ox is located on the rightside o> the dru%*

Maintenance Manual@ $a%pling 'nterval andocation o> $a%pling ?alve >or in>or%ation ono&taining the oil sa%ple >ro% the vi&rator) support*

9ote A>ter )ou o&tain an oil sa%ple@ add oil in orderto %aintain the proper level*

/al2-AroundIn%pection

SMCS Code. 1000#050( 000#050

i0120!1

'llustration /1+

g005+553!

9O:'CEAccu%ulated grease or oil on a %achine is a >irehaG#ard* Re%ove this de&ris ;ith stea% cleaning or highpressure ;ater at least ever) 1000 service hours or

atan) ti%e there is a signi>icant a%ount o> oil spilledon

1. Re%ove the level chec. plug 2* Maintain thelevel o> the oil to the &otto% o> the level chec.plug opening*

2. '> the oil level is lo;@ re%ove the oil >iller plug 1*

3. Add oil in order to %aintain the proper level*

4. Clean the level chec. plug and install the levelchec. plug* Clean the >iller plug and install the>iller plug*

the %achine*

9ote Chec. the %achine >or lea.s* '> a lea. is>ound@ >ind the source o> the lea.* Repair the lea. &e>ore )ou start the %achine* Chec. the >luid levels%ore >reDuentl) i> )ou suspect a lea.*

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Ma.e sure that all covers and guards are >ir%l) inplace* Chec. the guards and covers >or da%age*

'nspect the steps@ ;al.;a)s@ and handholds >orda%age or ;ear* Chec. the steps@ ;al.;a)s andhandholds >or cleanliness* 'nspect the Rollover

7rotective $tructure RO7$ >or da%age* '> repair isnecessar)@ consult )our Caterpillar dealer* :ightenan) loose &olts*

'nspect the operator co%part%ent >or cleanliness*Keep the operator co%part%ent clean*

'llustration /20

g00012+'> eDuipped@ ad6ust the rear vie; %irrors >or the &estvision*

Chec. the air >ilter service indicator* 8hen theindicator is red@ service the air >ilter ele%ent*

'llustration /22 g00012++

'llustration /21

g00"5+""'nspect the ru&&er isolation &loc.s >or da%[email protected]@ or splitting*

'nspect the lights >or &ro.en &ul&s or &ro.en lenses*Replace the &ul&s or the lenses i> the &ul&s or thelenses are &ro.en*

Re%ove an) trash in the engine co%part%ent*

'nspect the cooling s)ste% >or lea.s@ da%agedhoses@ or trash* Repair an) lea.s* Re%ove an) trash>ro% the radiator*

'nspect the engine attach%ents >or ;ear or

da%age* Replace an) co%ponents that are ;ornor da%aged*

'nspect the h)draulic s)ste% >or lea.s* 'nspectthe >ollo;ing co%ponents the h)draulic tan.@ thec)linder rod seals@ the hoses@ the lines@ and the>ittings* Repair an) lea.s* Repair an) da%agedco%ponents or ;orn co%ponents*

'nspect the rear axle >or an) lea.s*

/)eel Nut% - Ti8)ten

SMCS Code. 5210#!2

'llustration /2/

i012/211

g00""0+"

'nspect the tires >or da%age* Chec. the tires >orproper in>lation* Replace %issing valve caps*

:ighten the ;heel nuts to a torDue o> 5/0 "0 9%/20 55 l& >t*

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1/2Maintenance $ection8indo; 8asher Reservoir # ,ill

i0113+1

/indo= /a%)er Re%eroir -&ill(I6 E0uipped*

SMCS Code. /0"#!55

/indo= /iper -In%pect:Replace(I6 E0uipped*

SMCS Code. /0!#050( /0!#!10

i0113+++

'llustration /25 g00"1/!"+

'llustration /2"g00"32!!

:he ;indo; ;asher reservoir is located on the rightside o> the ca&* 'nspect the >ront ;indshield ;iper &lade and the

rear ;indshield ;iper &lade* '> necessar)@ replacethe ;indshield ;iper &lades*

/indo=% - Clean(I6 E0uipped*

SMCS Code. /10#00

i01/12/

'llustration /2!

g00"1/!"0

Use co%%erciall) availa&le ;indo; cleaningsolutions in order to clean the ;indo;s* Clean theoutside o> the ca& ;indo;s >ro% the ground unlesshandholds are availa&le*

'> the level o> the cleaning solution is lo;@ re>ill thereservoir*

Documents

KEBU7506-01 M