mneumatics compactor

7/28/2019 Mneumatics Compactor

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2010 CaterpillarAll Rights Reserved

MAINTENANCE INTERVALSOperation and MaintenanceManual Excerpt


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KEBU7534-03

February 2008

Operation andMaintenance

ManualPS-150C Paving Compactor

FPS1-Up (Machine)

SAFETY.CAT.COM


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58 KEBU7534-03Maintenance SectionMaintenance Interval Schedule

i02932670

Maintenance Interval Schedule

SMCS Code: 1000; 7000

Ensure that all safety information, warnings andinstructions are read and understood before anyoperation or any maintenance procedures areperformed.

The user is responsible for the performance ofmaintenance, including all adjustments, the use ofproper lubricants, fluids, filters, and the replacementof components due to normal wear and aging. Failureto adhere to proper maintenance intervals andprocedures may result in diminished performance ofthe 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 conditionsmay require more frequent maintenance.

Note: Before each consecutive interval is performed,all maintenance from the previous interval must beperformed.

When Required

Ballast - Remove/Install ........................................ 62Battery - Recycle .................................................. 63Battery or Battery Cable - Inspect/Replace .......... 63

Circuit Breakers - Reset ........................................ 65Engine Air Filter Primary Element - Clean/Replace ............................................................... 72

Engine Air Filter Secondary Element - Replace ... 74Engine Compartment - Clean ............................... 75Fuel System - Prime ............................................. 78Fuses - Replace .................................................... 79Oil Filter - Inspect .................................................. 84Radiator and Hydraulic Oil Cooler - Clean ............ 85Tire Mat - Replace ................................................ 88Tire Scraper - Inspect/Adjust/Replace .................. 88Water Spray Nozzles - Clean ................................ 89Water Spray System - Drain ................................. 90Water Spray System Filter - Clean ....................... 90

Wheel Nuts - Tighten ............................................ 92

Every 10 Service Hours or Daily

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

Every 50 Service Hours or Weekly

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

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

Every 250 Service Hours or 3 Months

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

Initial 500 Hours (for New Systems, Refilled

Systems, and Converted Systems)

Cooling System Coolant Sample (Level 2) -Obtain ................................................................. 68

Every 500 Service Hours


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

Every 500 Service Hours or 6 Months

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

Every 1000 Service Hours or 1 Year

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

Replace/Clean .................................................... 78Hydraulic System Oil Filter - Replace ................... 81


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KEBU7534-03 59Maintenance Section

Maintenance Interval Schedule

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

Every 2000 Service Hours or 1 Year

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

Every Year


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 orEvery 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


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60 KEBU7534-03Maintenance Section

Air Compressor Air Filter - Clean/Inspect

i02067645

Air Compressor Air Filter -Clean/Inspect

SMCS Code: 1803-571-FI

g01059409Illustration 51

1. Remove the cover for the airfilter housing.

2. Clean the inside of the air filter housing.

3. Clean the airfilter element.

Note: Use pressurized air in order to clean the airfilter element.

4. Inspect the airfilter element for tears and/or holes.Discard the airfilter element if the airfilter element

is damaged.

5. Install the airfilter element.

6. Install the cover for the airfilter housing.

i02067647

Air Compressor Air Filter -Replace



1. Remove the cover from the air intake housing.

2. Remove the airfilter element.

3. Install a new airfilter element.

4. Install the cover for the air intake housing.

i02071762

Air Compressor Oil - ChangeSMCS Code: 1803-044-OC; 1803-510-OC


1. Place a suitable container under the drain plug.Remove the drain plug. Refer to the Operationand Maintenance Manual, General HazardInformation for information that pertains tocontaining fluid spillage.

2. Allow the oil to completely drain.


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Air Compressor Oil - Check

3. Clean the drain plug. Install the drain plug.

Note: Dispose of the used oil according to localregulations.

4. Fill the crankcase for the air compressor to the

correct fluid level.

i02071466

Air Compressor Oil - Check

SMCS Code: 1803-535-FLV


Maintain the oil level between the two level markson the dipstick. Do not fill above the second markon the dipstick.

i02065499

Air Tank Moisture andSediment - Drain

SMCS Code: 5505-543


Open the valve in order to drain the moisture fromthe air tank.

i02051981

Backup Alarm - Test

SMCS Code: 7406-081


The backup alarm is located at the rear of themachine.

1. Turn the battery disconnect switch clockwise inorder to turn the electrical system ON.

2. Turn the engine start switch to the ON position inorder to perform the test.


3. Apply the parking brake (1). Move the propelcontrol lever (2) to the REVERSE position.

Note: The backup alarm should start to soundimmediately.

4. The backup alarm will continue to sound until thepropel control lever is moved to the NEUTRALposition or to the FORWARD position.


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62 KEBU7534-03Maintenance SectionBallast - Remove/Install

i02051996

Ballast - Remove/Install

SMCS Code: 7056-011; 7056-012

g00894838

Illustration 58Drain for liquid ballast

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


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


3. Remove the four platform covers.

4. Use a shovel or use a water hose in order to cleanthe solid ballast through the outlet opening of theballast compartment.

5. Install the outlet cover.

6. Install the solid or liquid ballast in the ballastcompartments in order to maintain proper balanceof the machine.

7. Install the platform covers.

i01740120

Battery - Clean/Check

SMCS Code: 1401-535

Personal injury may occur from failure to properlyservice the batteries.

Batteries give off flammable fumes that can ex-plode. Electrolyte is an acid and can cause per-sonal injury if it contacts the skin or eyes.

Prevent sparks near the batteries. Sparks couldcause vapors to explode. Do not allow jumper ca-ble ends to contact each other or the engine. Im-proper jumper cable connections can cause an ex-plosion.

Always wear protective glasses when workingwith batteries.

1. Open the engine compartment.


Right side of machine

Note: The batteries that are supplied with themachines are maintenance free batteries. You donot need to check the level of the electrolyte in themaintenance free batteries.


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Battery - Recycle

2. Tighten the battery retainers on the battery atevery 1000 hours.

3. Check the following items at every 1000 hours. Ifnecessary, check the following items more often.

a. Clean the top of the batteries with a clean cloth.

b. Clean the battery terminals. As needed, coatthe battery terminals with petroleum jelly.

4. Close the engine compartment.

i00993589

Battery - Recycle

SMCS Code: 1401-561

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the followinglocations:

A battery supplier

An authorized battery collection facility

Recycling facility

i02932445

Battery or Battery Cable -

Inspect/Replace

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

Personal injury can result from battery fumes orexplosion.

Batteries give off flammable fumes that can ex-plode. Electrolyte is an acid and can cause per-sonal injury if it contacts the skin or eyes.

Prevent sparks near the batteries. Sparks couldcause vapors to explode. Do not allow jumper ca-ble ends to contact each other or the engine. Im-proper jumper cable connections can cause an ex-plosion.

Always wear protective glasses when workingwith batteries.

1. Turn the engine start switch key to the OFFposition. Turn all of the switches to the OFFposition.

2. Turn the battery disconnect switch to the OFFposition. Remove the key.

3. Disconnect the negative battery cable at thebattery.

4. Disconnect the positive battery cable at thebattery.

5. Disconnect the battery cables at the batterydisconnect switch. The battery disconnect switchis connected to the machine frame.

6. Make necessary repairs or replace the battery.

7. Connect the battery cable at the battery disconnectswitch.

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 disconnectswitch to the ON position.

i02079674

Belts - Inspect/Adjust/Replace

SMCS Code: 1357-025; 1357-040; 1357-510

Your engine can be equipped with a fan drive beltand with accessory drive belts. Your engine can also

be equipped with an alternator belt. For maximumengine performance and maximum utilization of yourengine, inspect the belts for wear and for cracking.Check the belt tension. Adjust the belt tension inorder to minimize belt slippage. Belt slippage willdecrease the belt life. Belt slippage will also causepoor performance of the alternator and of any drivenequipment.

If new belts are installed, recheck the belt adjustmentafter 30 minutes of operation. If two belts or more arerequired for an application, replace the belts in beltsets. If only one belt of a matched set is replaced, thenew belt will carry more load. This is due to the fact

that the older belts are stretched. The additional loadon the new belt could cause the new belt to break.

Alternator Belt

1. Stop the engine.



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64 KEBU7534-03Maintenance SectionBraking System - Test


3. To check the belt tension, apply 110 N (25 lb)of force midway between the pulleys. Correctlyadjusted belts will deflect 14 to 20 mm

(1/2 to 3/4 inch).

4. In order to adjust the alternator belt, loosen thealternator adjusting bracket bolt and the mountingbracket bolt.

5. To achieve the correct belt tension, move thealternator inward or move the alternator outward,as required.

6. If necessary, use a pry bar to bear against thealternator bracket.

7. Tighten the mounting bracket bolt and the

alternator adjusting bracket bolt.

8. If new belts are installed, check the belt adjustmentagain after 30 minutes of engine operation at therated speed.

9. Check the position of the fan shroud. Adjust theposition of the fan shroud so that the fan willnot rub against the shroud. Maintain a 9.4 mm(0.38 inch) clearance between the fan and theshroud.

i02136804

Braking System - TestSMCS Code: 4250-081; 4251-081; 4267-081

Parking Brake Holding Ability Test

Note: If the machine configuration changes, theparking brakes need to be tested.

Check the area around the machine. Make surethat the machine is clear of personnel and clear ofobstacles.

Fasten the seat belt before checking the parkingbrake.

The following tests are used to determine if theparking brake is functional on a specified grade ora specified slope. These tests are not intended to

measure the maximum brake holding effort. Readall of the steps before you perform the followingprocedure.


Position the machine on the incline of the slope, butnear the base of the slope in order to check theparking brake. The test position should be 26 percentor a 15 degree slope.

1. Start the engine. Refer to the Operation andMaintenance Manual, Engine Starting forinformation on starting the engine.

2. Move the machine into the test position.

3. Place the throttle control into the LOW IDLEposition.

4. Engage the parking brake.

The machine should not move under the followingconditions.

The engine is at low idle.

The parking brake is applied.

The machine is positioned on the specifiedslope.


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Circuit Breakers - Reset

Personal injury can result if the machine moveswhile testing.

If the machine begins to move, place the throttlecontrol in HIGH IDLE, release the parking brakeand use the propel lever in order to move the ma-chine to a level surface.

5. Park the machine on a level surface.

6. Stop the engine.

NOTICEIf the machine moved during the brake test, consultyour Caterpillar dealer.

The dealer must inspect the brake system and makeany necessary repairs before the machine is returnedto operation.

i02052020

Circuit Breakers - Reset

SMCS Code: 1420-529

The circuit breaker panel is located in the enginecompartment.


Circuit Breaker/Reset Push in the buttonin order to reset the circuit breaker. If theelectrical system is functioning properly, the

button will remain depressed. If the button does notremain 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)

i02052146

Cooling System Coolant (ELC)- Change

SMCS Code: 1395-044-NL

Drain the coolant whenever the coolant is dirty. Drainthe coolant when foam is observed.

1. Stop the engine. Allow the cooling system to coolcompletely.

2. Open the hood for the engine.



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66 KEBU7534-03Maintenance SectionCooling System Coolant (ELC) - Change


Personal injury can result from hot coolant, steam

and alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant orsteam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly torelieve pressure only when engine is stopped andcooling system pressure cap is cool enough totouch with your bare hand.

Do not attempt to tighten hose connections whenthe 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 radiatorcap (1).

4. Remove the cap for expansion tank (3).

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, CaterpillarTools and Shop Products Guide for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

5. Drain valve (2) is located on the bottom cornerof the radiator. Open drain valve (2). Allow thecoolant to drain into a suitable container.

6. Close drain valve (2). Fill the radiator with asolution which consists of clean water and of

cooling system cleaner. Once the radiator is filled,fill the cooling system expansion tank to the fullline. The concentration of the cooling systemcleaner in the solution should be between 6percent and 10 percent.

7. Install radiator cap (1) and the cap for theexpansion tank (3).

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 coolcompletely.

10. Slowly loosen radiator cap (1) and removeradiator cap (1).

11. Remove the cap for expansion tank (3).

12. Drain the cleaning solution into a suitablecontainer.

13. While the engine is stopped, flush the system withwater. Flush the system until the draining wateris transparent.

14. Close drain valve (2).

NOTICEMixing Extended Life Coolant (ELC) with other prod-ucts reduces the effectiveness of the coolant andshortens coolant life. Use only Caterpillar prod-ucts or commercial products that have passed theCaterpillar EC-1 specifications for premixed or con-centrate coolants. Use only Caterpillar Extender withCaterpillar ELC. Failure to follow these recommenda-tions could result in the damage to cooling systemscomponents.

If ELC cooling system contamination occurs, refer to

Operation and Maintenance, Extended Life Coolant(ELC) under the topic ELC Cooling System Contam-ination.

15.Add the coolant solution. See the following topics:

Special Publication, SEBU6250, CaterpillarMachine Fluids Recommendations, CoolingSystem Specifications

Operation and Maintenance Manual, Capacities(Refill)


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Cooling System Coolant Extender (ELC) - Add

Note: If you are using Caterpillar antifreeze, do notadd the supplemental coolant additive at this time.

16. Start the engine. Run the engine without theradiator cap until the thermostat opens and thecoolant level stabilizes.

17. Completely fill the radiator.

Note: The radiator must remain completely full inorder 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 lineon expansion tank (4).

20. Install the cap for expansion tank (3).

21. Stop the engine.

22. Close the hood for the engine.

i02053058

Cooling System CoolantExtender (ELC) - Add

SMCS Code: 1352-544-NL

At operating temperature, the engine coolant ishot and under pressure.

Steam can cause personal injury.

Check the coolant level only after the engine hasbeen stopped and the fill cap is cool enough totouch with your bare hand.

Remove the fill cap slowly to relieve pressure.

Cooling system conditioner contains alkali. Avoidcontact with the skin and eyes to prevent personal

injury.

When a Caterpillar Extended Life Coolant (ELC) isused, an Extender must be added to the coolingsystem.

Use a 8T-5296 Coolant Test Kit to check theconcentration of the coolant.

Refer to the Special Publication, SEBU6250,Caterpillar Machines Fluids Recommendations,Cooling System Specifications for more informationabout the addition of Extender.

NOTICETopping off or mixing Cat ELC with other products thatdo not meet Caterpillar EC-1 specifications reducesthe effectiveness of the coolant and shortens coolantservice life.

Use only Caterpillar products or commercial productsthat have passed the Caterpillar EC-1 specification forpre-mixed or concentrate coolants. Use only Extenderwith Cat ELC.

Failure to follow these recommendations can result inshortened cooling system component life.

1. Stop the engine. Allow the cooling system tocompletely cool.



3. Remove the cap for the expansion tank.

4. Add the recommended amount of extenderto the coolant system. Refer to the SpecialPublication, SEBU6250, Caterpillar MachinesFluids Recommendations, Cooling SystemSpecifications for the proper amount.

5. Maintain the level of the coolant to the full line onthe cooling system expansion tank.

Note: The radiator must remain completely full inorder for the expansion tank to work properly.

6. Install the cap for the expansion tank.



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68 KEBU7534-03Maintenance SectionCooling System Coolant Sample (Level 1) - Obtain

i02053348

Cooling System CoolantSample (Level 1) - Obtain

SMCS Code: 1395-008

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.

Note: Level 1 results may indicate a need forLevel 2 Analysis.


Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In orderto receive the full effect of SOS analysis, youmust establish a consistent trend of data. In orderto establish a pertinent history of data, performconsistent samplings that are evenly spaced.Supplies for collecting samples can be obtained fromyour Caterpillar dealer.

Use the following guidelines for proper sampling ofthe coolant:

Complete the information on the label for thesampling bottle before you begin to take thesamples.

Keep the unused sampling bottles stored in plasticbags.

Obtain coolant samples directly from the coolantsample port. You should not obtain the samplesfrom any other location.

Keep the lids on empty sampling bottles until youare ready to collect the sample.

Place the sample in the mailing tube immediatelyafter obtaining the sample in order to avoidcontamination.

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, seeSpecial Publication, SEBU6250, Caterpillar MachineFluids Recommendations or consult your Caterpillardealer.

i02053351

Cooling System CoolantSample (Level 2) - Obtain

SMCS Code: 1350-008; 1395-008

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.


Obtain the sample of the coolant as close as possibleto the recommended sampling interval. Suppliesfor collecting samples can be obtained from yourCaterpillar dealer.

Refer to Operation and Maintenance Manual,Cooling System Coolant Sample (Level 1) - Obtainfor the guidelines for proper sampling of the coolant.

Submit the sample for Level 2 analysis.


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Cooling System Coolant Level - Check

For additional information about coolant analysis, seeSpecial Publication, SEBU6250, Caterpillar MachineFluids Recommendations or consult your Caterpillardealer.

i02053493

Cooling System Coolant Level- Check






Cooling system conditioner contains alkali. Avoidcontact with the skin and eyes to prevent personalinjury.



2. Maintain the level of the coolant in the expansiontank to the level line.


i02053503

Cooling System Pressure Cap- Clean/Replace

SMCS Code: 1382-070; 1382-510



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

Personal injury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant orsteam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly torelieve pressure only when engine is stopped andcooling system pressure cap is cool enough totouch with your bare hand.

Do not attempt to tighten hose connections whenthe coolant is hot, the hose can come off causingburns.

Cooling System Coolant Additive contains alkali.Avoid contact with skin and eyes.

3. Remove the cooling system pressure cap slowlyin order to relieve pressure.

4. Inspect the cooling system pressure cap forforeign material, for deposits, and for damage.Clean the cooling system pressure cap with aclean cloth. If the cooling system pressure cap isdamaged, replace the cooling system pressurecap.


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70 KEBU7534-03Maintenance SectionCooling System Water Temperature Regulator - Replace

5. Install the cooling system pressure cap.


i02053644

Cooling System WaterTemperature Regulator -Replace

SMCS Code: 1355-510; 1393-010

Replace the water temperature regulator on a regularbasis in order to reduce the chance of unscheduleddowntime and of problems with the cooling system.

The water temperature regulator should be replacedafter the cooling system has been cleaned. Replace

the water temperature regulator while the coolingsystem is completely drained. Replace the watertemperature regulator while the cooling systemcoolant is drained to a level below the watertemperature regulator housing.

NOTICEFailure to replace the engines water temperature reg-ulator on a regularly scheduled basis could cause se-vere engine damage.

Note: If you are only replacing the water temperatureregulator, drain the cooling system coolant to a

level that is below the water temperature regulatorhousing.







Cooling system conditioner contains alkali. Avoidcontact with the skin and eyes to prevent personalinjury.

2. Remove radiator cap (1) in order to relieve thepressure in the cooling system.

3. Loosen hose clamp (2) and remove hose (3) fromwater temperature regulator housing (4).

4. Remove bolts (5) from water temperatureregulator housing (4) and remove watertemperature regulator housing (4).

5. Remove the gasket and remove the watertemperature regulator from the water temperatureregulator housing. Make a note of the orientationof the old regulator.

NOTICEThe water temperatureregulators maybe reused if thewater temperature regulators are within test specifica-tions, are not damaged, and do not have excessivebuildup of deposits.

NOTICESince Caterpillar engines incorporate a shunt designcooling system, it is mandatory to always operate theengine with a water temperature regulator.

Depending on load, failure to operate with a watertemperature regulator could result in either an over-

heating or an overcooling condition.

NOTICEIf the water temperature regulator is installed incor-rectly, it will cause the engine to overheat.

6. Install a new water temperature regulator. Orientthe regulator in the same manner as the oldregulator. Install a new gasket. Install the watertemperature regulator housing.

7. Install the water temperature regulator housingand the hose. Tighten the hose clamp.


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Crankshaft Vibration Damper - Inspect


8. Add the cooling system coolant. Maintain the levelof the coolant to the full line on the cooling systemexpansion tank.

Note: The radiator must be completely full in orderfor the expansion tank to work properly.

9. Inspect cooling system pressure cap and thegasket for damage. Replace the pressure cap ifthe pressure cap or the gasket are damaged.

10. Install the cooling system pressure cap.


i01735165

Crankshaft Vibration Damper- Inspect

SMCS Code: 1205-040

Open the engine compartment.



Damage to the crankshaft vibration damper or failureof the crankshaft vibration damper can increasetorsional vibrations. This can result in damage to

the crankshaft and to other engine components. Adeteriorating damper can cause excessive gear trainnoise at variable points in the speed range.

The damper is mounted to the crankshaft on the frontof the engine.

Visually inspect the crankshaft vibration damper fordamage.

Check the bolts for proper tightness. Refer toSpecification, SENR3130, Torque Specifications.

Close the engine compartment.

i02176959

Drive Shaft - Lubricate

SMCS Code: 3253-086

Accidental machine starting can cause injury ordeath to personnel working on the machine.

To avoid accidental machine starting, turn the bat-

tery disconnect switch to the OFF position and re-move the key. If the machine is not equipped witha battery disconnect switch, disconnect the bat-tery cables from the battery and tape the batteryclamps.

Place a do not operate tag at the battery discon-nect switch location to inform personnel that themachine is being worked on.

1. Shut off the engine.



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72 KEBU7534-03Maintenance SectionEngine Air Filter Primary Element - Clean/Replace

3. Turn the battery disconnect switch to the OFFposition.

4. Wipe all fittings, caps, and plugs on the two driveshafts before servicing.


Right drive shaft

5. Lubricate the hydraulic fitting on each drive shaft.

6. Turn the battery disconnect switch to the ONposition.


i01953476

Engine Air Filter Primary

Element - Clean/ReplaceSMCS Code: 1054-070-PY; 1054-510-PY

NOTICEService the air cleaner only with the engine stopped.Engine damage could result.

Service the air cleanerfilter element when theyellow piston on the engine airfilter serviceindicator enters the red zone or the indicatorreads 63.5 cm (25 inch) of water. Refer toOperation and Maintenance Manual, Engine Air

Filter Service Indicator - Inspect.


1. Remove cover (1) for the airfilter housing.

2. Remove primary filter element (2) from the air

filter housing.

3. Clean the inside of the air filter housing.

4. If the machine is equipped with a vacuator valve,clean the vacuator valve on the cover for the airfilter housing.

5. Install a clean primary airfilter element. Install thecover for the airfilter housing.

Note: Refer to Cleaning Primary Air Filter Elements.

6. Reset the engine airfilter service indicator.

7. Close the access door.

If the yellow piston in the indicator moves into the redzone after starting the engine or the exhaust smokeis still black after installation of a clean primary filterelement, install a new primary filter element. If thepiston remains in the red zone replace the secondaryelement.


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Engine Air Filter Primary Element - Clean/Replace

Cleaning Primary Air FilterElements

NOTICECaterpillar recommends certified airfilter cleaning ser-

vices available at participating Caterpillar dealers. TheCaterpillar cleaning process uses proven proceduresto assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt toclean the filter element:

Do not tap or strike the filter element in order to re-move dust.

Do not wash the filter element.

Use low pressure compressed air in order to removethe dust from the filter element. Air pressure must not

exceed 207 kPa (30 psi). Direct the air flow up thepleats and down the pleats from the inside of the filterelement. Take extreme care in order to avoid damageto the pleats.

Do not use airfilters with damaged pleats, gaskets, orseals. Dirt entering the engine will cause damage toengine components.

The primary airfilter element can be used up to sixtimes if the element is properly cleaned and if theelement is properly inspected. When the primaryairfilter element is cleaned, check for rips or tearsin the filter material. The primary airfilter elementshould be replaced at least one time per year. Thisreplacement should be performed regardless of thenumber of cleanings.

NOTICEDo not clean the airfilter elements by bumping or tap-ping. This could damage the seals. Do not use ele-ments with damaged pleats, gaskets, or seals. Dam-aged elements will allow dirt to pass through. Enginedamage could result.

Visually inspect the primary airfilter elements before

cleaning. Inspect the airfi

lter elements for damageto the seal, the gaskets, and the outer cover. Discardany damaged airfilter elements.

There are two common methods that are used toclean primary airfilter elements:

Pressurized air

Vacuum cleaning

Pressurized Air

Pressurized air can be used to clean primary airfilterelements that have not been cleaned more than twotimes. Pressurized air will not remove deposits ofcarbon and oil. Use filtered, dry air with a maximum

pressure of 207 kPa (30 psi).


Note: When the primary air filter elements arecleaned, always begin with the clean side (inside)in order to force dirt particles toward the dirty side(outside).

Aim the hose so that the airflows inside the elementalong the length of the filter in order to help preventdamage to the paper pleats. Do not aim the stream ofair directly at the primary airfilter element. Dirt couldbe forced further into the pleats.

Vacuum Cleaning

Vacuum cleaning is another method for cleaningprimary airfilter elements which require daily cleaningbecause of a dry, dusty environment. Cleaning withpressurized air is recommended prior to vacuumcleaning. Vacuum cleaning will not remove depositsof carbon and oil.


19/37

74 KEBU7534-03Maintenance SectionEngine Air Filter Secondary Element - Replace

Inspecting the Primary Air FilterElements


Inspect the clean, dry primary airfilter element. Use

a 60 watt blue light in a dark room or in a similarfacility. Place the blue light in the primary air filterelement. Rotate the primary airfilter element. Inspectthe primary airfilter element for tears and/or holes.Inspect the primary airfilter element for light that mayshow through the filter material. If it is necessary inorder to confirm the result, compare the primary airfilter element to a new primary airfilter element thathas the same part number.

Do not use a primary airfilter element that has anytears and/or holes in the filter material. Do not usea primary air filter element with damaged pleats,gaskets or seals. Discard damaged primary air filterelements.

Storing Primary Air Filter Elements

If a primary airfilter element that passes inspectionwill not be used, the primary air filter element canbe stored for future use.


Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. An airflow restrictionmay result. To protect against dirt and damage, wrapthe primary airfilter elements in Volatile CorrosionInhibited (VCI) paper.

Place the primary airfilter element into a box forstorage. For identification, mark the outside of thebox and mark the primary airfilter element. Includethe following information:

Date of cleaning

Number of cleanings

Store the box in a dry location.

i02080824

Engine Air Filter SecondaryElement - Replace

SMCS Code: 1054-510-SE

NOTICEAlways replace the secondary filter element. Never at-tempt to reuse the secondary filter element by clean-ing the element.

When the primary filter element is replaced, the sec-ondary filter element should be replaced.

The secondary filter element should also be replacedif the exhaust smoke is still black.


2. See Operation and Maintenance Manual, EngineAir Filter Primary Element - Clean/Replace.Remove the air cleaner cover from the air cleanerhousing. Remove the primary filter element fromthe air cleaner housing.


3. Remove the secondary filter element.


20/37


Engine Air Filter Service Indicator - Inspect

4. Cover the air inlet opening. Clean the inside ofthe air cleaner housing.

5. Remove the cover from the air inlet opening.

6. Install the new secondary filter element.

7. Install the primary filter element.

8. Install the air cleaner cover and close the latchessecurely.


i02055014

Engine Air Filter ServiceIndicator - Inspect

SMCS Code: 7452-040



2. Clean the air intake system.

a. Squeeze rubberflap (2)in order to remove dirtfrom the dust ejector.

3. Start the engine.

4. Run the engine at high idle.

5. If the yellow piston in engine air filter serviceindicator (1) enters the red zone, service the aircleaner.

6. Press the end of the indicator in order to reset theindicator 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.


i01404793

Engine Compartment - Clean

SMCS Code: 1000-070

NOTICEBefore spraying the engine compartment with highpressure water turn off the engine and allow the en-gine to cool. Do not spray water directly on a hot fuelinjection pump or damage may occur.

Use a commercially available engine degreaserin order to clean the engine compartment. Usecaution and minimize the water around bearings andelectrical connections.

i02055145

Engine Oil Level - Check


NOTICEDo not underfill or overfill engine crankcase with oil.Either condition can cause engine damage.

Stop the engine in order to check the oil level. DONOT check the oil level when the engine is running.

Park the machine on a level surface.




21/37

76 KEBU7534-03Maintenance SectionEngine Oil Sample - Obtain

2. Remove dipstick (2). Wipe the dipstick with a cleancloth. Insert the dipstick. Remove the dipstick andnote the oil level. Insert the dipstick.

Note: Refer to the Operation and MaintenanceManual, Lubricant Viscosities for more information

on the correct grade of engine oil to use. Refer toOperation and Maintenance Manual, Capacities(Refill) for the correct amount of oil that is usedwhen the oil is changed. The correct amount of oildetermines the correct level of the oil in the FULLrange on the dipstick.

NOTICEDo not overfill the crankcase. The oil level must notreach the top of the FULL range mark or above theFULL range mark.

3. Maintain the oil level on the dipstick between the

FULL RANGE mark and the ADD OIL mark . Addoil if the oil level is too low.

Note: Operating your engine with the oil level abovethe FULL mark in the FULL Range could causethe crankshaft to dip into the oil. This could resultin excessively high operating temperatures. Thehigh operating temperatures could result in reducedlubricating characteristics of the oil. This could causedamage to the bearings and loss of engine power.

4. If the oil level is correct, close the enginecompartment.

Add The Engine Oil

1. Remove oil filler cap (1).

2. Add the oil so that the oil is at the correct level.

3. Clean the oil filler cap. Install the oil filler cap.


i02055157

Engine Oil Sample - Obtain

SMCS Code: 1000-008

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.


Obtain a sample of the engine oil from engine oilsampling valve (1) that is located on the engineoil filter housing. Refer to Special Publication,SEBU6250, SOS Oil Analysis for information thatpertains to obtaining a sample of the engine oil.Refer to Special Publication, PEHP6001, How ToTake A Good Oil Sample for more information aboutobtaining a sample of the engine oil.

i02055163

Engine Oil and Filter - Change

SMCS Code: 1318-510

Run the engine in order to warm up the oil. Stopthe engine before you drain the oil. When the oil iswarm the waste particles are suspended in the oil.The waste particles will be removed when the oil isdrained.

As the oil cools, the waste particles settle to thebottom of the oil pan. The waste particles will not beremoved if the oil is too cool.

The waste particles can recirculate through theengine lubrication system if the recommendedprocedure is not followed.



22/37


Engine Valve Lash - Check


Some components have been removed in order to clearly showthe components.

(1) Oil filler cap(2) Filter element

(3) Dipstick(4) Drain valve

2. Place a suitable container under the drain valve.Open drain valve (4). Refer to the Operationand Maintenance Manual, General HazardInformation for information that pertains tocontaining fluid spillage.

3. Allow the oil to completely drain.


5. Remove filter element (2).

Note: Dispose of the used filter element accordingto local regulations.

6. Clean the filter housing base. All of the old filterseal must be removed from the filter housing base.

7. Apply a thin coat of engine oil to the seal of thenew filter element.

8. Install the new filter by hand. When the sealcontacts the base, tighten the filter element foran additional 3/4 turn. This will tighten the filtersufficiently.

Every new oil filter has rotation index marks thatare spaced at 90 degree increments. Use therotation index marks as a guide for tightening theoil filter.

9. Remove oil filler cap (1). Fill the crankcasewith new oil. See Operation and MaintenanceManual, Capacities (Refill). See Operation andMaintenance Manual, Lubricant Viscosities.Clean the oil filler cap and install the oil filler cap.

10. Before you start the engine, check the oil level ondipstick (3). The oil level must be within the FULLRANGE 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 todrain back into the crankcase. Check the oil level.Maintain the oil level within the FULL RANGE onthe dipstick.


i01897328

Engine Valve Lash - Check

SMCS Code: 1105-535

Note: A qualified service person should perform thevalve lash check and/or the valve lash adjustment.Special tools and training are required.

Refer to your machines Service Manual for completeinstructions.

i02075239

Engine Water Pump - Inspect

SMCS Code: 1361-040

A water pump that has failed might cause severeengine overheating. Severe engine overheatingcould result in the following problems:

Cracks in the cylinder head

Piston seizure

Other potential engine damage




23/37

78 KEBU7534-03Maintenance SectionFuel System - Prime

Water pump (1) is located on the engine block at thefront of the engine.

Visually inspect the water pump for leaks. If leaks arefound, all the seals must be replaced.

i02090480

Fuel System - Prime

SMCS Code: 1250-548

This machines engine is equipped with an electronicfuel pump. Turn the engine start key to the ONposition in order to prime the fuel system. Check forleaks.

i02055316

Fuel System Water Separator- Drain

SMCS Code: 1263-543


2. The water separator is located in the enginecompartment on the back of the machine.


3. Open drain valve (1) that is located on the bottom

of the separator element. Allow the water andsediment to drain into a suitable container.


5. If the engine fails to start, change the fuel filter. Ifthere is a power loss, change the fuel filter.


i02055321

Fuel System Water SeparatorElement - Replace

SMCS Code: 1263-510-FQ



2. Open drain valve (2). Allow the fuel, the water andsediment to drain into a suitable container.

3. Remove housing (1) from the mounting base.

4. Remove the seal for housing (1).

5. Remove the filter element from housing (1).

6. Install the new filter 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 inorder to prime the fuel system. Check for leaks.


i02066954

Fuel Tank Cap Filter andStrainer - 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.


24/37


Fuel Tank Water and Sediment - Drain


2. Lift lever (1) and turn lever (1) counterclockwiseuntil the lever stops. Remove the cap.

3. Inspect seal (2) for damage. Replace the seal, ifnecessary.

4. Inspect filters (3). Clean the filters. Replace thefilters, if necessary.


5. Remove the strainer that is located in the filleropening.

6. Wash the strainer and the fuel tank cap in a clean,nonflammable solvent.

7. Apply a thin film of fuel to the gasket of the fueltank cap.

8. Install the fuel tank cap.

i02066986

Fuel Tank Water and Sediment- Drain

SMCS Code: 1273-543-M&S


The drain valve is located on the bottom of the fueltank. Drain the water and the sediment into a suitablecontainer. Refer to the Operation and MaintenanceManual, General Hazard Information for informationthat pertains to containing fluid spillage. Close thedrain valve.

Note: Dispose of all fluids according to localregulations.

i02050186

Fuses - Replace

SMCS Code: 1417-510

Fuse The fuses protect the electricalsystem from damage that is caused byoverloaded circuits. Change the fuse if the

element separates. If the element of the new fuseseparates, check the circuit. Repair the problembefore you operate the machine.

NOTICE

Replace fuses with the same type and size. Improp-er use of fuses could result in electrical damage. Fre-quent replacement of fuses may indicate another typeof electrical problem. Contact your Caterpillar dealer.


25/37

80 KEBU7534-03Maintenance SectionHydraulic System Oil - Change


Backup Alarm (1) 10 amp

Glow Plugs (2) 10 amp

Flashers (3) 10 amp

Pump for Tire Inflation (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 personalinjury. Do not allow hot oil or hot components tocontact skin.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-

ing any compartment or disassembling any compo-nent containing fluids.



Note: Cleanliness must be a priority when youchange the hydraulic oil.

Note: Change the oil in a clean work area. Use cleantools. Make sure that you have clean hands.

1. Operate the machine enough to warm the oil. Themachine should be level with the parking brakeengaged and the engine stopped.



3. Remove the hydraulic tank filler cap.


26/37


Hydraulic System Oil Filter - Replace


4. Remove the drain plug from the bottom of thehydraulic 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, approvedhydraulic oil. Refer to the Operation andMaintenance Manual, Lubricant Viscosities andOperation and Maintenance Manual, Capacities(Refill) for more information. Clean the hydraulictank filler cap and install the filler cap.

7. Start the engine and allow the oil to warm. Stopthe engine.

8. Refer to illustration 93. Maintain the proper oillevel in the sight gauge. This level is between theFULL mark and the ADD mark on the decalnext to the sight glass.


i02055354

Hydraulic System Oil Filter -Replace

SMCS Code: 5068-510

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact skin.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-

ing any compartment or disassembling any compo-nent containing fluids.



NOTICETake extreme care to insure the cleanliness of the hy-

draulic oil. Keep the hydraulic oil clean in order to ex-tend the component life and assure the maximum per-formance.



2. Remove the hydraulic tank filler cap.


27/37

82 KEBU7534-03Maintenance SectionHydraulic System Oil Level - Check


3. The hydraulic oil filter is located toward the rightside of the machine.

4. Clean the hydraulic oil filter location.

5. Remove the filter with a strap type wrench.

6. Clean the filter housing base. Remove anyexisting gasket material.

7. Apply a light coat of hydraulic oil to the gasket onthe new filter.

8. Use your hand to install the new filter. When theseal contacts the base, tighten the filter elementfor an additional three quarters of a turn.

9. With the machine on level ground, check thehydraulic oil level in the sight gauge. The oil levelshould be visible in the sight gauge.

10.Add required oil. Refer to Operation andMaintenance Manual , Hydraulic System OilLevel - Check.


i01744155

Hydraulic System Oil Level -Check

SMCS Code: 5056-535-FLV; 5095-535-FLV



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


i02055511

Hydraulic System Oil Sample- Obtain

SMCS Code: 5056-008


The sampling port for the hydraulic oil is locatedon the inlet line for the hydraulic oil filter. Refer toSpecial Publication, SEBU6250, SOS Oil Analysisfor information that pertains to obtaining a sampleof the hydraulic oil. Refer to Special Publication,PEHP6001, How To Take A Good Oil Sample formore information about obtaining a sample of thehydraulic oil.


28/37


Hydraulic System Tank Vent - Replace

i02074965

Hydraulic System Tank Vent -Replace

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



Note: The vent is located on top of the hydraulic tank.

2. Remove the vent from the hydraulic tank.

3. Install a new vent.


i02072906

Hydraulic Tank Strainer - Clean

SMCS Code: 5056-070-STR


1. Remove the filler cap for the hydraulic tank.

2. Pull the strainer for the hydraulic tank out of thefiller tube.

3. Clean the strainer in clean, nonflammable solvent.Dry the strainer with compressed air.

4. Install the strainer and the filler cap.

i01746601

Indicators and Gauges - Test

SMCS Code: 7450-081



Right rear of machine

2. Turn the battery disconnect switch ON.


3. Look for broken gauges (1), indicator lights, orswitches on the instrument panel.

4. Do not start the engine, but turn the key startswitch (2) to ON. The alternator indicator light (3)and the parking brake indicator light (4) shouldbe on.

5. Observe any gauges that do not operate. Makeany needed repairs before operating the machine.


29/37

84 KEBU7534-03Maintenance SectionNeutral Start Switch - Test

i02055530

Neutral Start Switch - Test

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

The machine may lurch forward if the neutral startswitch is out of adjustment. Be sure the area isclear of all personnel and equipment before per-forming this test.

1. Turn the battery disconnect switch clockwise inorder to turn the electrical system ON.


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


3. Hold engine start switch (2) in the STARTposition. Slowly move the propel lever toward theNEUTRAL position.

4. If the engine starts before you move the propellever to the NEUTRAL position, the neutralstart switch requires adjustment. Do not operatethe machine until the repairs have been made.Refer to the service manual for your machine forinstructions on adjusting the neutral start switch.

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

i02106227

Oil Filter - Inspect

SMCS Code: 1308-507; 3004-507; 3067-507;5068-507

Inspect a Used Filter for Debris


The element is shown with debris.

Use a filter cutter to cut the filter element open.Spread apart the pleats and inspect the element formetal and for other debris. An excessive amount ofdebris in the filter element can indicate a possible

failure.

If metals are found in the filter element, a magnet canbe used to differentiate between ferrous metals andnonferrous metals.

Ferrous metals can indicate wear on steel parts andon cast iron parts.

Nonferrous metals can indicate wear on thealuminum parts of the engine such as main bearings,rod bearings, or turbocharger bearings.

Small amounts of debris may be found in the filter

element. This could be caused by friction and bynormal wear. Consult your Caterpillar dealer in orderto arrange for further analysis if an excessive amountof debris is found.

Using an oil filter element that is not recommendedby Caterpillar can result in severe engine damageto engine bearings, to the crankshaft, and to otherparts. This can result in larger particles in unfilteredoil. The particles could enter the lubricating systemand the particles could cause damage.


30/37


Oscillating and Steering Bar - Lubricate

i01749852

Oscillating and Steering Bar -Lubricate

SMCS Code: 4313-086

Kingpin Bearing Lubrication


Lubrication point for kingpin assembly

1. Wipe all fittings, caps and plugs before servicing.

2. Lubricate the fitting for the oscillating and steeringbar, as shown.

i02055537

Radiator and Hydraulic OilCooler - Clean

SMCS Code: 1353-070-KO; 1374-070

NOTICEHigh pressure water can damage the radiator.

Use a water spray nozzle on the pressure washer thatwill disperse the water pressure.



The radiator core is located directly behind thehydraulic oil cooler. Inspect the hydraulic oil coolerand the radiator core for debris. If necessary, cleanthe hydraulic oil cooler and the radiator core.

Compressed air is preferred, but high pressure wateror steam can be used to remove dust and generaldebris from the oil cooler and the radiator core. Cleanthe cores according to the condition of the cores.

Note: High pressure water can bend the oil coolerand the radiatorfins.

See Special Publication, SEBD0518, Know YourCooling System for more detailed information aboutcleaning radiatorfins.

Close the engine compartment.


31/37

86 KEBU7534-03Maintenance SectionRollover Protective Structure (ROPS) - Inspect

i02055555

Rollover Protective Structure(ROPS) - Inspect

SMCS Code: 7323-040


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 equipmentparts only. Tighten the mounting bolts for the ROPSto a torque of 800 100 Nm (592 74 lb ft). Thereis a total of 16 mounting bolts for the ROPS. Themounting bolts for the ROPS are located at thebottom 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 theROPS.

i02429589

Seat Belt - Inspect

SMCS Code: 7327-040

Always check the condition of the seat belt and thecondition of the seat belt mounting hardware before

you operate the machine. Replace any parts that aredamaged or worn before you operate the machine.


Typical example

Check the seat belt mounting hardware (1) for wearor for damage. Replace any mounting hardware that

is worn or damaged. Make sure that the mountingbolts are tight.

Check buckle (2) for wear or for damage. If the buckleis worn or damaged, replace the seat belt.

Inspect the seat belt (3) for webbing that is worn orfrayed. Replace the seat belt if the seat belt is wornor frayed.

Consult your Caterpillar dealer for the replacement ofthe seat belt and the mounting hardware.

Note: Within three years of the date of installation or

within five years of the date of manufacture, replacethe seat belt. Replace the seat belt at the date whichoccurs first. A date label for determining the age ofthe seat belt is attached to the seat belt, the seat beltbuckle, and the seat belt retractor.

If your machine is equipped with a seat beltextension, also perform this inspection procedure forthe seat belt extension.

i02429594

Seat Belt - Replace

SMCS Code: 7327-510

Within three years of the date of installation or withinfive years of the date of manufacture, replace theseat belt . Replace the seat belt at the date whichoccurs first. A date label for determining the age ofthe seat belt is attached to the seat belt, the seat beltbuckle, and the seat belt retractor.


32/37


Steering Cylinder Ends - Lubricate


(1) Date of installation (retractor)(2) Date of installation (buckle)(3) Date of manufacture (tag) (fully extended web)(4) Date of manufacture (underside) (buckle)

Consult your Caterpillar dealer for the replacement of

the seat belt and the mounting hardware.

If your machine is equipped with a seat beltextension, also perform this replacement procedurefor the seat belt extension.

i01743968

Steering Cylinder Ends -Lubricate

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

Steering Cylinder


Right side of machine

1. Lubricate one fitting on each end of the steeringcylinder from each side of the machine.

i02055592

Strainer (Flushing System) -Clean


Personal injury can result from hydraulic oil pres-sure and hot oil.

Hydraulic oil pressure can remain in the hydraulicsystem after the engine has been stopped. Seri-ous injury can be caused if this pressure is not re-leased before any service is done on the hydraulicsystem.

Make sure all of the work tools have been lowered

to the ground, and the oil is cool before removingany components or lines. Remove the oil filler caponly when the engine is stopped, and the filler capis cool enough to touch with your bare hand.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.



Park the machine on a level surface. Ensure that theparking brake is fully engaged. Shut off the engine.Remove the oil filler cap for the hydraulic tank.

The strainer for system flushing is located inside theengine compartment on left side of the machine.


33/37

88 KEBU7534-03Maintenance SectionTire Inflation - Check


1. Loosen top hose (1) and cap the hose. Removecover (2).

2. Remove the strainer from the housing.

3. Clean the strainer. Use a nonflammable solventin order to clean the strainer. If the strainer isdamaged, replace the strainer. Consult yourCaterpillar dealer for replacement parts.

4. Install the strainer.

5. Install cover (2) and top hose (1). Install the oilfiller cap for the hydraulic tank.

i01784823

Tire Inflation - CheckSMCS Code: 4203-535-PX

Personal injury can result from improper tire infla-tion.

A tire blowout or rim failure can result from im-proper or misused equipment.

Use a self-inflating chuck and stand behind the

tread when inflating a tire.

Proper inflating equipment, and training in usingthe equipment, are necessary to avoid overinflat-ing.

Before inflating tire, put the tire in a restrainingdevice.

Measure the tire pressure on each tire. Consult yourCaterpillar dealer for the correct load rating and forthe correct operating pressures.

Inflate the tires, if necessary. See Operation andMaintenance Manual, Tire Inflation Information forinformation about tire inflation, tire pressures, andtire inflation pressure adjustment.

i01747479

Tire Mat - Replace

SMCS Code: 6611-510

Block the machine in order to prevent unexpectedmovement of the machine. Failure to do so mayresult in personal injury or death.


1. Remove the bolts and remove the damaged mat.

2. Install the new mat. Install the bolts.

i02064840

Tire Scraper - Inspect/Adjust/Replace

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

Block the machine in order to prevent unexpectedmovement of the machine. Failure to do so mayresult in personal injury or death.


34/37


Toggle Switch - Inspect


Inspect tire scrapers (1) and clean the scrapers.Adjust tire scrapers (1) so that the tire scrapers arecentered across the tire.

Replace the tire scrapers if the tire scrapers aredamaged.

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 tirescraper is centered across the tires.

i02711091

Toggle Switch - Inspect

SMCS Code: 7332-040


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

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

1. Turn the engine start switch to the OFF position.Do not test the switches when the machine isrunning.

2. Visually inspect the area around the seal (3). Lookfor 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 testfor 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). Ifthe switch has an incorrect displacement, replacethe switch. Repeat the measurement when youpress the switch downward.

i02137293

Water Spray Nozzles - CleanSMCS Code: 6609-070


Rear spray nozzles


Front spray nozzles

1. Remove the caps and the screens.

2. Clean the screens in nonflammable solvent.


35/37

90 KEBU7534-03Maintenance SectionWater Spray System - Drain

3. Install the screens and caps.

i01742647

Water Spray System - Drain

SMCS Code: 5612-543

NOTICEDrain the water spray system completely when freez-ing conditions exist. This is done inorder to avoid dam-age to the water spray system.


1. Remove the drain plug from the water tank.


2. Remove the waterfilter, if equipped.

3. Install the waterfilter and install the drain plug.

4. Close the valve.

i02067469

Water Spray System Filter -Clean


NOTICEDrain the water spray system completely when freez-ing conditions exist. This is done in order to avoid dam-age to the water spray system.

1. Remove the drain plug in order to drain the watertank. See Operation and Maintenance Manual,Water Spray System - Drain.


Waterfilter (if equipped)

2. The waterfilter is located under the water tank onthe front side of the machine.

3. In order to remove the filter bowl, turn the filterbowl in a counterclockwise direction.

4. Remove the screen from the filter bowl.

5. Wash the filter bowl and the screen in clean,nonflammable solvent. Dry the components withpressure air.

6. Replace any components that are damaged.

7. Reverse the removal steps in order to install thewater spray system filter.

8. Install the drain plug in the water tank.

9. Fill the water tank with clean water. See Operationand Maintenance Manual, Capacities (Refill).


36/37


Water Tank Strainer - Clean and Inspect

i02075250

Water Tank Strainer - Cleanand Inspect



1. Remove the filler cap.

2. Remove the strainer.

3. Clean the filler cap with clean water or compressedair.

4. Clean the strainer with clean water or compressedair.

5. Install the strainer.

6. Fill the tank with clean water.

7. Install the filler cap.

i01743693

Wheel Bearings (Front) -Lubricate

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


To avoid accidental machine starting, turn the bat-tery disconnect switch to the OFF position and re-move the key. If the machine is not equipped witha battery disconnect switch, disconnect the bat-tery cables from the battery and tape the batteryclamps.

Place a do not operate tag at the battery discon-nect switch location to inform personnel that themachine is being worked on.


1. Wipe all fittings, caps, and plugs before servicing.


Front wheels

2. Use the hydraulic fittings and lubricate each of thewheel bearings (five wheels).


37/37

92 KEBU7534-03Maintenance SectionWheel Nuts - Tighten

i01742826

Wheel Nuts - Tighten

SMCS Code: 4210-527


To avoid accidental machine starting, turn the bat-tery disconnect switch to the OFF position and re-move the key. If the machine is not equipped witha battery disconnect switch, disconnect the bat-tery cables from the battery and tape the batteryclamps.

Place a do not operate tag at the battery discon-nect switch location to inform personnel that the

machine is being worked on.


1. Tighten the front wheel bolts to a torque of155 14 Nm (115 10 lb ft).

2. Tighten the rear wheel nuts to a torque of238 20 Nm (175 15 lb ft).

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