INTERVALOS DE MANTENIMIENTO - KEBU7506-01 M

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MANTENIMIENTO

Transcript of INTERVALOS DE MANTENIMIENTO - KEBU7506-01 M

2010 CaterpillarAll Rights ReservedMAINTENANCE INTERVALSOperation and Maintenance Manual ExcerptKEBU7506-01September 2001Operation andMaintenanceManualCS-531D, CP-533DandCS-533DVibratory CompactorsAFC1-Up (Machine)AGH1-Up (Machine)AET1-Up (Machine)76Maintenance SectionMaintenance Interval Schedulei01600251Maintenance Interval ScheduleSMCS Code: 1000;7000When RequiredBattery - Recycle.................................................. 80Cab Air Filter - Clean/Replace .............................. 82Circuit Breakers - Reset ........................................ 83CuttingEdges(LevelingBlade)-Inspect/Replace ............................................................... 93Drum Cooling Oil - Change ................................... 94Drum Scrapers - Inspect/Adjust/Replace .............. 95EngineAir Filter PrimaryElement -Clean/Replace.................................................. 101Engine Air Filter Secondary Element - Replace .. 102Ether Starting Aid Cylinder - Replace ................. 109Fuel System - Prime ........................................... 112Fuel System Water Separator - Drain ................. 116Fuses - Replace .................................................. 119Oil Filter - Inspect ................................................ 126Radiator Core - Clean ......................................... 126Wheel Nuts - Tighten .......................................... 131Window Washer Reservoir - Fill .......................... 132Window Wiper - Inspect/Replace ........................ 132Windows - Clean ................................................. 132Every 10 Service Hours or DailyBackup Alarm - Test .............................................. 79Cooling System Level - Check .............................. 90Engine Air Filter Service Indicator - Inspect ........ 103Engine Oil Level - Check.................................... 105Hydraulic System Oil Level - Check .................... 122Indicators and Gauges - Test .............................. 124Neutral Start Switch - Test.................................. 125Walk-Around Inspection ...................................... 130Every 50 Service Hours or WeeklyFuel Tank Water and Sediment - Drain ............... 118Leveling Blade - Lubricate.................................. 125Steering Cylinder Ends - Lubricate ..................... 127Tire Inflation - Check ........................................... 129Initial 250 Service HoursAxle Oil (Rear) - Change...................................... 78Drum Support Oil - Change .................................. 96Engine Valve Lash and Injector Fuel Timing -Check/Adjust ..................................................... 109Final Drive Planetary (Axle) Oil - Change ........... 110Final Drive Planetary (Drum) Oil - Change ......... 111Hydraulic System Oil Filter - Replace ................. 121Every 250 Service Hours or 3 MonthsAir Conditioner - Test ............................................ 78Axle Oil Level (Rear) - Check............................... 78Belts - Inspect/Adjust/Replace .............................. 81Cooling System Coolant Additive (DEAC) - Add ... 87Drum Support Oil - Check.................................... 97Engine Oil Sample - Obtain................................ 106Engine Oil and Filter - Change........................... 107Final Drive Planetary (Axle) Oil Level - Check .... 111Final Drive Planetary (Drum) Oil - Check........... 112Vibratory Support Oil Level - Check................... 130Every 500 Service Hours or 6 MonthsAxle Oil Sample - Obtain...................................... 79Cooling System Coolant Sample - Obtain............ 89Drum Support Oil Sample - Obtain ....................... 97Final DrivePlanetary(Axle)Oil Sample-Obtain............................................................... 111Final DrivePlanetary(Drum)Oil Sample-Obtain............................................................... 112Fuel SystemPrimaryFilter-Clean/Inspect/Replace ............................................................. 113Fuel System Secondary Filter - Replace ............ 114Fuel SystemWaterSeparatorElement -Replace ............................................................. 116Hydraulic System Oil Sample - Obtain............... 123Vibratory Support Oil Sample - Obtain............... 130Every 1000 Service Hours or 1 YearAxle Oil (Rear) - Change...................................... 78Battery - Clean/Check ........................................... 79Battery or Battery Cable - Replace ....................... 80Cooling System Coolant Sample - Obtain............ 89Cooling System Pressure Cap - Clean/Replace ... 91Drum Support Oil - Change .................................. 96Engine Crankcase Breather - Clean ................... 104Engine Mounts - Inspect ..................................... 105Final Drive Planetary (Axle) Oil - Change ........... 110Final Drive Planetary (Drum) Oil - Change ......... 111Fuel Tank Breather - Replace ............................. 117Fuel Tank Cap and Strainer - Clean................... 118Hydraulic System Oil - Change ........................... 120Hydraulic System Oil Filter - Replace ................. 121Hydraulic Tank Strainer - Clean.......................... 123Hydraulic Tank Vent - Replace ............................ 124Rollover Protective Structure (ROPS) - Inspect .. 127Vibratory Support Oil - Change.......................... 129Every 2000 Service Hours or 2 YearsCrankshaft Vibration Damper - Inspect ................. 93EngineGovernor Oil SupplyScreen-Clean/Inspect/Replace ...................................... 104Engine Valve Lash and Injector Fuel Timing -Check/Adjust ..................................................... 109Every 2000 Service Hours or 1 YearTilt Hood Actuator - Lubricate ............................. 128Every 3000 Service Hours or 2 YearsCooling System Coolant (DEAC) - Change.......... 83Cooling System Water Temperature Regulator -Replace ............................................................... 9177Maintenance SectionMaintenance Interval ScheduleEngine Water Pump - Inspect ............................. 109Every 3 YearsSeat Belt - Replace ............................................. 127Every 3000 Service Hours or 3 YearsCooling System Coolant Extender (ELC) - Add .... 88Eccentric Weight Housing Oil - Change............... 97Every 6000 Service Hours or 6 YearsCooling System Coolant (ELC) - Change ............. 8578Maintenance SectionAir Conditioner - Testi01084958Air Conditioner - Test(If Equipped)SMCS Code: 7320-081Before warm weather begins, check the refrigerant.Alsocheck therefrigerantifthe airconditioningsystem does not function properly.Open the engine compartment.When the outside temperature is higher than 21 C(70 F), operate the air conditioning system for fivetoten minutes.Whenthesystemneedsrefrigerant, seeyourCaterpillar dealer for proper installation.Operatetheairconditionermonthlyinordertolubricate the compressor seals. Set the controls onthe maximum setting.Operatethe systemfor15minutes.Close the engine compartment.i01234081Axle Oil (Rear) - ChangeSMCS Code: 3260-044g00659994Illustration 1431. Remove the differentialdrain plug. The plug islocated at the bottom of the differential case.Note: Drain the oil into a suitable container. Disposeof the used oil in an appropriate manner.2. Removethedifferential level/fill plug. Thedifferentiallevel/fill plug is locatedon the backsideoftheaxle.3. Clean the drain plug and install the drain plug.Addthe properoil tothe differential.Maintainthelevel oftheoil tothebottomoftheholeforthedifferential level/fill plug.RefertotheOperation and Maintenance Manual, LubricantViscositiesandRefill Capacitiessectionformoreinformation.4. Clean the filler plug. Install the filler plug.i01224219Axle Oil Level (Rear) - CheckSMCS Code: 3260-535-FLVg00654323Illustration 144Note: The differentiallevel/fill plug is located on thebackside of the rearaxle.1. Remove the level/fill plug. Maintain the oil leveltothe bottomofthelevel/fill plug opening.Ifnecessary,add oil.2. Clean the level/fill plug. Install the plug.79Maintenance SectionAxle Oil Sample - Obtaini01316767Axle Oil Sample - ObtainSMCS Code: 3260-008g00659994Illustration 145Thedrain plugislocatedonthebottomofthedifferential.Refer totheCaterpillar MachineFluidsRecommendations, SEBU6250,CoolingSystemspecificationsandrefertotheOperationandMaintenanceManual, SamplingInterval andLocation of Sampling Valve for more information.i01179669Backup Alarm - TestSMCS Code: 7406-081Thebackupalarm islocatedattherearofthemachine.g00701234Illustration 146Turn the engine start switch to the ON position inorderto perform the test.Apply the parking brake. Movethe propel controllever to the REVERSEposition.The backup alarm should start to sound immediately.The backup alarm willcontinue to sound until thetransmissioncontrol leveris movedto the STOPposition or to the FORWARDposition.g00100238Illustration 147Inordertoadjust thevolumelevel, turnthethree-position selector switch. The switch is locatedon the back of the backup alarm. When the machineisshippedfromthefactory,thethree-positionselectorswitchissettotheHIGHsetting.Thethree-position selector switch should remain at theHIGH setting unless the job site requiresa lowervolumelevel.i01179702Battery - Clean/CheckSMCS Code: 1401-535g00646983Illustration 14880Maintenance SectionBattery - Recycleg00611761Illustration 149Note: Thebatteriesthat aresuppliedwiththemachines are maintenancefree batteries.You donot need to check the level of the electrolyte in themaintenance freebatteries.Tighten the battery retainers on both of the batteries.Tighten the battery retainers at every 1000 hours.Check the following items at every 1000hours. Ifnecessary, check the following items more often.Clean the top of the batteries with a clean cloth.Clean the battery terminals. As needed, coat thebattery terminals with petroleum jelly.i00836435Battery - RecycleSMCS Code: 1401-561Always recycle a battery. Never discard a battery.Always return used batteries to one of the followinglocations:A batterysupplierAn authorized battery collection facilityRecycling facilityi01179721Battery or Battery Cable -ReplaceSMCS Code: 1401-510; 1402-5101. Turn the engine start switch to the OFF position.Turn all switches to the OFF position.2. Turn the engine start switch to the OFF position.Turn all switches to the OFF position.g00646983Illustration 150g00611761Illustration 1513. Open the batterycompartments. There isonecompartment on each side of the machine.4. At the battery disconnect switch, disconnect thenegativebattery cablewhichis connectedtotheframe.Note: Do not allow the disconnected battery cablesto contact the disconnect switch. Do not allow thedisconnected battery cables to contactthe othercables. Donotallowthedisconnectedbatterycables to contacttheoppositeterminalof eitherbattery.5. Disconnectthenegativebattery cableatthebattery.6. Disconnectthenegativebattery cableatthebattery.7. Removethe negativebatterycablefromthesecondbattery.Thiswillallow youto removethecable.81Maintenance SectionBelts - Inspect/Adjust/Replace8. Removethe +batterycable fromthe secondbattery.Inordertoremovethecablethatconnects the two batteries, you must remove twoclamps. The two clamps are located undertheradiator at the rear of the machine.9. Remove the cable from the starter motor.10. Performthenecessaryrepairs.Replacethecables or the batteries, as needed.11. Reverse the above steps in order to reconnectthebatteries.12. Connect thebatterycableat thebatterydisconnectswitch.13. Install the battery disconnectswitch key.Turnthe battery disconnect switch to the ON position.14. Install the battery compartment covers.i01431376Belts - Inspect/Adjust/ReplaceSMCS Code: 1357-025; 1357-040; 1357-510Yourengine canbe equipped with a waterpumpbelt, with a fan drive belt and with accessory drivebelts.Your enginecan also beequipped with analternator belt. For maximum engine performanceandmaximumutilizationof your engine,inspectthe belts for wear and for cracking. Check the belttension. Adjust the belt tension in order to minimizebelt slippage. Belt slippagewill decreasethe beltlife. Belt slippage will also cause poor performanceof the alternator and of any driven equipment.If newbeltsareinstalled, recheckthebeltadjustment after 30 minutes of operation. If two beltsor more are required for an application, replace thebelts in belt sets. If only one belt of a matched setis replaced, the new belt will carry more load. Thisis due to the fact that the older belts are stretched.The additional load on the new belt could cause thenewbeltto break.g00647005Illustration 152Open the engine compartment.Alternator Beltg00484481Illustration 1531. Tocheck the belt tension,apply 110 N (25 lb)of force midway between the pulleys. Correctlyadjustedbeltswill deflect 13to19mm(1/2to 3/4inch).2. Inordertoadjustthealternatorbelt,loosenbracketbolt (1)andmountingbolt(2) onthealternatorbracket.3. Toachievethecorrectadjustment,movethealternator inward or move the alternator outward,asrequired.4. If necessary, use a pry bar in the square hole (3)inthe alternator bracket.5. Tighten mounting bolt (2) and bracket bolt (1).6. If newbeltsareinstalled, checkthebeltadjustment again after30minutesofengineoperationat the high speed.82Maintenance SectionCab Air Filter - Clean/Replace7. Check the position of the fan shroud. Adjust thepositionofthe fanshroudso thatthefan willnot rub against the shroud. Maintain a 9.4 mm(0.38 inch) clearance between the fan andtheshroud.Water Pump Belt1. Tocheck the belt tension,apply 110 N (25 lb)of force midway between the pulleys. Correctlyadjustedbeltswill deflect 13to19mm(1/2to 3/4inch).g00613760Illustration 1542. Toadjustthewaterpumpdrivebelt,loosenmounting bolt (1) and bracket bolt (3).3. Moveidlerpulley (4)inordertoachievethecorrectadjustment.4. If necessary, use a pry bar in square hole (2) inthe mountingbracket.5. Tighten mounting bolt (1) and bracket bolt (3).6. If a new belt is installed, run the engine at ratedspeed for thirty minutes. Check the bolt torque.Readjust the belt, if necessary.i01316775Cab Air Filter - Clean/Replace(If Equipped)SMCS Code: 7342-070; 7342-510The cab air filter is located to the left of the seat.g00645572Illustration 1551. Remove the two hand knobs (1).2. To remove the filters, pull upward on the handle(2).g00645580Illustration 1563. Clean the filters (3), or replace the filters.4. Install the filters in the reverse order of the abovesteps.83Maintenance SectionCircuit Breakers - Reseti01597151Circuit Breakers - ResetSMCS Code: 1420-529g00568429Illustration 157The circuit breakers are located on the front of theoperator console. In order to remove the cover (1),remove the four screws. There is one screw at eachcorner ofthe cover.After all of therepairsarecompleted, placethecoveroverthecircuitbreakers. Install thefourscrews.Circuit Breaker/Reset Push in the buttonin order to resetthe circuit breaker. If theelectrical system is functioningproperly,thebuttonwill remaindepressed. Ifthebuttondoes not remain depressed, check the appropriateelectrical circuit.Repairtheelectrical circuit,ifnecessary.g00568430Illustration 158Circuit breaker (2)isdesignedtoprotecttheelectronic throttle. The circuit breaker has a capacityof15Amp.Circuit breaker (3)isdesignedtoprotectthealternator. For example, if the batteries are installedwithreversedpolarity,the circuitbreakerwouldprevent the alternator fromdamaging the rectifier.The circuit breaker has a capacity of 60 Amp.i01200479CoolingSystemCoolant(DEAC) - ChangeSMCS Code: 1352-544; 1395-044Personal injury can result from hot coolant, steamand alkali.At operatingtemperature, enginecoolant ishotandunder pressure. Theradiator andall linestoheatersortheenginecontainhot coolant orsteam. Any contact can cause severe burns.Removecoolingsystempressurecapslowlytorelieve pressure only when engine is stopped andcoolingsystempressurecapiscool enoughtotouch 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.Note: This procedure pertains to Caterpillar DieselEngine Antifreeze/Coolant(DEAC) only.This doesnot pertain to machines that are shipped fromthefactory with Extended Life Coolant (ELC). This doesnot pertainto machines thatare maintainedwithExtended Life Coolant (ELC).NOTICEDo not change the coolant until you read and under-standthematerial intheCoolingSystemSpecifica-tions section.84Maintenance SectionCooling System Coolant (DEAC) - ChangeNOTICECare 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-inganycompartment or disassemblinganycompo-nent containing fluids.Refer to Special Publication, NENG2500, CaterpillarTools and Shop Products Guide for tools and suppliessuitabletocollect andcontainfluidsonCaterpillarproducts.Dispose of all fluids according to local regulations andmandates.If the coolant is dirty or if you observe any foamingin the cooling system, drain the coolant before therecommendedinterval.Itis importantto replacethe thermostat inorderto avoidany unexpectedfailure of the thermostat.This is a good preventive maintenance practice thatreducesthe chancesof unscheduleddowntime.Failuretoreplacethe thermostatonaregularlyscheduledbasiscouldcausesevereenginedamage.Note: If you are only replacing the thermostat, drainthe coolant from the cooling system so that the levelof the coolant is below the thermostat housing.Always operate Caterpillar engines with a thermostatbecause these engines have a shunt design coolingsystem.Note: Thermostats can be reused if the thermostatsmeet certaintest specifications. Thetestedthermostats must not be damaged and the testedthermostats must nothave anexcessive buildupofdeposits.1. Stop the engine and allow the engine to cool.g00647005Illustration 1592. Open the engine compartment.g00614264Illustration 1603. Slowly remove the cooling system pressure capinorder to relievepressure.g00614249Illustration 1614. Open the drain valve that is under the radiator.Allowthecoolant todrainintoasuitablecontainer.5. Close the drain valve. Fill the cooling system withclean water and with a 6 to 10% concentration ofcoolingsystemcleaner.6. Start the engine. Run the engine for 90 minutes.7. Stop the engine. Drain the cleaning solution.8. Flushthecoolingsystemwithwateruntil thedraining wateris transparent.9. Closethe drain valve.10. Add the coolant solution. Refer to Operation andMaintenance Manual, Refill Capacities.85Maintenance SectionCooling System Coolant (ELC) - ChangeNote: If you are using Caterpillar Long Life Coolantthat containssomeadditive, donotaddanysupplemental coolant additive at this time . Also, donot change the coolant conditioner element if youare using Caterpillar Long Life Coolant that containssomeadditive.11. Take off the cooling system pressure cap. Startthe engine and run the engine. Leave the cap offuntil the thermostat opens and the coolant levelstabilizes.g00614280Illustration 16212. Maintain the coolant to the middle of the sightgauge.13. Replace the cooling system pressure cap if thegasket is damaged.Install the coolingsystempressurecap.14. Stopthe engine.15. Close the engine compartment.i01431098Cooling System Coolant (ELC)- ChangeSMCS Code: 1395-044-NLPersonal injury can result from hot coolant, steamand alkali.At operatingtemperature, enginecoolant ishotandunder pressure. Theradiator andall linestoheatersortheenginecontainhot coolant orsteam. Any contact can cause severe burns.Removecoolingsystempressurecapslowlytorelieve pressure only when engine is stopped andcoolingsystempressurecapiscool enoughtotouch 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.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-inganycompartment or disassemblinganycompo-nent containing fluids.Refer to Special Publication, NENG2500, CaterpillarTools and Shop Products Guide for tools and suppliessuitabletocollect andcontainfluidsonCaterpillarproducts.Dispose of all fluids according to local regulations andmandates.NOTICEDo not change the coolant until you read and under-standthematerial intheCoolingSystemSpecifica-tions section.86Maintenance SectionCooling System Coolant (ELC) - ChangeNOTICEMixing Extended Life Coolant (ELC) with otherproducts reduces the effectiveness of the coolantandshortenscoolantlife.UseonlyCaterpillarprod-uctsor commercial productsthat havepassedtheCaterpillar EC-1specificationsforpremixedorcon-centrate coolants. Use only Caterpillar Extender withCaterpillar ELC. Failure to follow these recommenda-tionscouldresultinthedamagetocoolingsystemscomponents.If ELC cooling system contamination occurs, refer toOperation andMaintenance, ExtendedLifeCoolant(ELC) under the topic ELC Cooling System Contam-ination.Drainthecoolantwheneverthecoolantisdirty.Drain the coolant when foam is observed.1. Stoptheengine.Allowthe coolingsystemtocool completely.g00647005Illustration 1632. Open the engine compartment.g00614264Illustration 1643. Slowly loosen the cooling system pressure capinorder to relieve the pressure.Slowly removethe cooling system pressure cap.g00614249Illustration 1654. The drain valve is located on the bottom cornerof the radiator.Open the drain valve. Allow thecoolant to drain into a suitable container.5. Closethedrain valve.Fill thesystemwithasolutionwhichconsistsof cleanwaterandofcooling system cleaner. The concentration of thecooling system cleaner in the solution should bebetween 6 percent and 10 percent.6. Start the engine. Run the engine for 90 minutes.Stop the engine. Drain the cleaning solution intoasuitablecontainer.7. Whilethe engine isstopped, flush the systemwith water.Flushthe systemuntil the drainingwateristransparent.Note: Check the water temperature regulator.Whilethe system isdrained, you might want to replacethe water temperatureregulator.8. Closethe drain valve.9. Addthecoolantsolution. Seethefollowingtopics:Special Publication,SEBU6250, CoolingSystem SpecificationsOperation andMaintenanceManual, RefillCapacitiesNote: If you are using Caterpillar antifreeze, do notadd the supplemental coolant additive at this timeand/or change the element at this time.10. Starttheengine.Runthe enginewithoutthecooling system pressure cap until the thermostatopens and the coolant level stabilizes.87Maintenance SectionCooling System Coolant Additive (DEAC) - Addg00614280Illustration 16611. Maintain the level of the coolant to the middle ofthesightgauge.12. Replace the cooling system pressure cap if thegasket is damaged.Install the coolingsystempressurecap.13. Stopthe engine.14. Close the engine compartment.i01200656CoolingSystemCoolantAdditive (DEAC) - AddSMCS Code: 1352-544At operatingtemperature, theenginecoolant ishot and under pressure.Steam can cause personal injury.Check the coolant level only after the engine hasbeenstoppedandthefillcapiscool enoughtotouch 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 personalinjury.See Caterpillar Machine Fluids Recommendations,SEBU6250, CoolingSystem Specification forallcooling systemrequirements.NOTICEExcessiveadditive(greater thantherecommended6%initial fill) together with concentrations of antifreezegreater than 60% cause deposits to form and can re-sult in radiator tube blockage and overheating.Use8T-5296Test Kit inordertochecktheconcentration.LiquidSupplemental CoolantAdditive1. Stoptheengine.Allowthe coolingsystemtocompletelycool.g00647005Illustration 1672. Open the engine compartment.g00614264Illustration 1683. Slowly loosen the cooling system pressure capin order to relieve system pressure. Remove thecooling systempressure cap.Note: Refer to Operation and Maintenance Manual,General HazardInformation forinformation onContaining Fluid Spillage.88Maintenance SectionCooling System Coolant Extender (ELC) - Add4. If necessary,drainenoughcoolantfromtheradiator in order to allow the addition of the liquidcoolantadditive.5. Add0.24Liters(.50pint)ofcoolingsystemadditive forevery 38 Liters(10 USGallons)ofengine coolingcapacity.6. Inspect thegasket forthecoolingsystempressure cap. Replace the cap if the gasket isdamaged.7. Install the cooling system pressure cap.8. Close the engine compartment.i01200670CoolingSystemCoolantExtender (ELC) - AddSMCS Code: 1352-544-NLAt operatingtemperature, theenginecoolant ishot and under pressure.Steam can cause personal injury.Check the coolant level only after the engine hasbeenstoppedandthefillcapiscool enoughtotouch 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 personalinjury.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-inganycompartment or disassemblinganycompo-nent containing fluids.Refer to Special Publication, NENG2500, CaterpillarTools and Shop Products Guide for tools and suppliessuitabletocollect andcontainfluidsonCaterpillarproducts.Dispose of all fluids according to local regulations andmandates.When a CaterpillarExtended Life Coolant (ELC) isused, an Extendermust be addedto the coolingsystem.Usea8T-5296CoolantTest Kittochecktheconcentration of the coolant.NOTICEMixingELCwithother products that donot meetCaterpillar EC-1 specifications reduces the effective-ness of the coolant and shortens coolant service life.Use only Caterpillar products or commercial productsthat havepassedtheCaterpillar EC-1specificationfor pre-mixed or concentrate coolants. Use onlyCaterpillar Extender with Caterpillar ELC.Failure to follow these recommendations can result inshortened cooling system component life.1. Stoptheengine.Allowthe coolingsystemtocompletelycool.g00647005Illustration 1692. Open the engine compartment.g00614264Illustration 1703. Slowly loosen the cooling system pressure capin order to relieve system pressure. Remove thecooling systempressure cap.4. If necessary,drainenoughcoolantfromtheradiatorinordertoallowtheadditionoftheExtender.89Maintenance SectionCooling System Coolant Sample - Obtain5. Add the recommended amount of extender to thecoolant system. Refer to the Caterpillar MachinesFluids Recommendations, SEBU6250, CoolingSystem Specifications for the proper amount.g00614280Illustration 1716. Maintain the level of the coolant to the middle ofthesightgauge.7. Inspect thegasket onthecoolingsystempressurecap. Replacethecoolingsystempressure cap if the gasket is damaged.8. Install the cooling system pressure cap.9. Close the engine compartment.i01200845CoolingSystemCoolantSample - ObtainSMCS Code: 1395-008At operatingtemperature, theenginecoolant ishot and under pressure.Steam can cause personal injury.Check the coolant level only after the engine hasbeenstoppedandthefillcapiscool enoughtotouch 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 personalinjury.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-inganycompartment or disassemblinganycompo-nent containing fluids.Refer to Special Publication, NENG2500, CaterpillarTools and Shop Products Guide for tools and suppliessuitabletocollect andcontainfluidsonCaterpillarproducts.Dispose of all fluids according to local regulations andmandates.1. Stoptheengine.Allowthe coolingsystemtocompletelycool.g00647005Illustration 1722. Open the engine compartment.g00614264Illustration 1733. Carefully loosen the cooling system pressure capin order to relieve system pressure.90Maintenance SectionCooling System Level - Checkg00614249Illustration 1744. The radiator drain valve is located at the rear ofthemachine.5. Opentheradiatordrainvalve.Allowsomecoolant to drain into a suitable container beforethesample istaken. Excessivesediment candrain away, and a more accurate sample results.Obtain asampleinanappropriatecontainer.Close the radiator drain valve.6. Send the coolant sample to an appropriate labfor analysis.See the Caterpillar Machine FluidsRecommendations, SEBU6250, SOS CoolantAnalysissection.7. Refill thecoolingsystemwithcoolant, asrequired. SeeCaterpillarMachineFluidsRecommendations, SEBU6250, Cooling SystemSpecifications.g00614280Illustration 1758. Maintain the level of the coolant to the middle ofthesightgauge.9. Tighten the cooling system pressure cap.10. Close the engine compartment.i01200889Cooling System Level - CheckSMCS Code: 1350-535-FLV; 1395-535-FLVAt operatingtemperature, theenginecoolant ishot and under pressure.Steam can cause personal injury.Check the coolant level only after the engine hasbeenstoppedandthefillcapiscool enoughtotouch 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 personalinjury.g00647953Illustration 1761. Open the access door onthe rightside of themachine.g00614280Illustration 1772. Maintainthelevel of thecoolant inthesightglass. The sight glass is located near the upperradiatorhose.91Maintenance SectionCooling System Pressure Cap - Clean/Replacei01200906Cooling System Pressure Cap- Clean/ReplaceSMCS Code: 1382-070; 1382-510Personal injury can result from hot coolant, steamand alkali.At operatingtemperature, enginecoolant ishotandunder pressure. Theradiator andall linestoheatersortheenginecontainhot coolant orsteam. Any contact can cause severe burns.Removecoolingsystempressurecapslowlytorelieve pressure only when engine is stopped andcoolingsystempressurecapiscool enoughtotouch 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.g00647005Illustration 1781. Open the engine compartment.g00614264Illustration 1792. The cooling systempressure cap is on the toprightrear of the machine.3. Remove the cooling system pressure cap slowlyinorder to relievepressure.4. Inspectthe coolingsystempressurecapforforeignmaterial, for deposits, and for damage.Cleanthe cooling systempressure capwith aclean cloth. If the cooling system pressure cap isdamaged, replace the cooling system pressurecap.5. Install the cooling system pressure cap.6. Close the engine compartment.i01201000CoolingSystemWaterTemperatureRegulator-ReplaceSMCS Code: 1355-510; 1393-010At operatingtemperature, theenginecoolant ishot and under pressure.Steam can cause personal injury.Check the coolant level only after the engine hasbeenstoppedandthefillcapiscool enoughtotouch 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 personalinjury.92Maintenance SectionCooling System Water Temperature Regulator - ReplaceReplacethewatertemperatureregulatoronaregularbasisinordertoreducethechanceofunscheduled downtimeand of problemswith thecoolingsystem.The water temperature regulator should be replacedafter the cooling system has been cleaned. Replacethe water temperatureregulator while the coolingsystemis completely drained.Replace the watertemperatureregulatorwhilethecoolingsystemcoolant isdrainedtoalevel belowthewatertemperature regulatorhousing.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,drainthe coolingsystemcoolanttoalevel that is below the water temperature regulatorhousing.g00647005Illustration 1801. Open the engine compartment.g00614264Illustration 1812. Removethe coolingsystempressurecapinordertorelievethepressureinthecoolingsystem.g00410105Illustration 1823. Loosen the hose clamp (4) and remove the hose(1) from the water temperature regulator housing(3).4. Remove the bolts (2) from the water temperatureregulatorhousing(3)andremovethewatertemperature regulator housing (3).5. Removethegasket andremovethewatertemperature regulator from the water temperatureregulator housing. Make a note of the orientationof theold regulator.NOTICEThe water temperature regulators may be reused if thewater temperature regulators are within test specifica-tions, arenot damaged, anddonot haveexcessivebuildup 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 water tem-perature regulator could result in either an overheatingor an overcooling condition.NOTICEIf thewatertemperatureregulatorisinstalledincor-rectly, it will cause the engine to overheat.6. Install a new water temperature regulator. Orienttheregulatorinthe samemanneras theoldregulator. Install a new gasket. Install the watertemperature regulatorhousing.7. Install the watertemperature regulator housingand the hose. Tighten the hose clamp.93Maintenance SectionCrankshaft Vibration Damper - Inspect8. Addthe coolingsystemcoolant. Maintainthelevel of thecoolantto the middleof the sightglass.9. Inspectcoolingsystempressure capandthegasket for damage. Replace the pressure cap ifthe pressure cap or the gasket are damaged.10. Install the cooling system pressure cap.11. Close the engine compartment.i01201253Crankshaft Vibration Damper- InspectSMCS Code: 1205-040g00647005Illustration 183Open the engine compartment.g00701237Illustration 184g00380076Illustration 185Damagetothecrankshaftvibrationdamperorfailureofthecrankshaftvibrationdampercanincreasetorsional vibrations.Thiscanresultindamagetothecrankshaftandtootherenginecomponents.A deterioratingdampercancauseexcessive gear train noise at variable points in thespeedrange.Thedamper ismounted to the crankshaft on thefrontof theengine.Visually inspect the crankshaft vibration damper fordamage.Checktheboltsforpropertightness.Refertothe Operation andMaintenance Manual, TorqueSpecifications.Close the engine compartment.i01193164Cutting Edges (Leveling Blade)- Inspect/ReplaceSMCS Code: 6801-040; 6801-510Personal injury or death can result if the levellingblade is not blocked up. Block the levelling bladebefore changing the cutting edge.94Maintenance SectionDrum Cooling Oil - Changeg00646073Illustration 186Therearetwo cuttingedgesonthefrontoftheblade (1). There are two skid plates on the bottomofthe blade(2).Replacethe cuttingedgeifthecuttingedgeisdamaged. Replace the cutting edge if the cuttingedge isexcessively worn.1. Raise the leveling blade. Block the leveling bladesecurely.Placethe blocks underthe arms(3)oftheblade.2. Remove the bolts. Remove the cutting edge.3. Cleanthe contact surfaces.4. If the oppositeedge of the cutting edge is notworn,usetheoppositeedge.Iftheoppositeedge is worn, replace the cutting edge.5. Install thebolts. Tightentheboltstothetorquesthat arespecifiedintheOperationandMaintenance Manual, Torquesfor GroundEngagingTool Bolts.6. Inspect the skid plates. Replace the skid platesif the skid plates are damaged or worn.7. Raise the leveling blade. Remove the blocks.8. Lower the leveling blade to the ground.9. Checkthe boltsforpropertorqueafterafewhoursof operation.i01234514Drum Cooling Oil - ChangeSMCS Code: 6605-044-OCg00660231Illustration 187Note: Cleantheareaaroundthefill/drainplugbeforeservicing the drum.Thedrumcoolingoil requiresservice whenthedisassemblyof the drumor the assemblyof thedrumisneeded.Rotate the fill/drain plug to the bottom of the drum.Removethedrain plug.Pumptheoil outofthedrum.Use the drain plug opening in order to fill the cavity.Install the plug after adding the correct amount ofoil. The oil will be near the bottom of the opening.In order to check the level of the oil, rotate the drumso the plug is at the bottom of the drum. Remove theplug. Maintain the oil to the bottom of the opening.Refer to the Operation andMaintenance Manual,LubricantViscositiesandtheOperationandMaintenance Manual, Refill Capacities.95Maintenance SectionDrum Scrapers - Inspect/Adjust/Replacei01200381DrumScrapers-Inspect/Adjust/ReplaceSMCS Code: 6607-025; 6607-040; 6607-510SmoothDrumScrapers(IfEquipped)Flexible Scrapersg00648069Illustration 188g00443291Illustration 189g00612356Illustration 190There are two scrapers. One scraper is in front ofthe drum. The second scraper is at the rear of thedrum.Adjust1. Inspect the scraper (3). Clean the scraper of dirtanddebris.2. Loosenthe bolts(4) thatareholdingthe rearflexiblescraper bladeandthe backing platestothe bracket.3. Loosenthe nuts (1)that hold the frontflexiblescraperbladeandthe backingplatestothebracket.Note: Whenyou adjustthe scraper(3), thesteelbacking plates (2) must not come into contact withthe surfaceof the drum.4. Adjust the flexible scraper blades (2) to 7 mm(0.25 inch) away from the surface of the drum.The backing plates (2) must be set back 35 mm(1.375 inch) from the end of the scraper. Adjustthe scraper blades (3) and the backing platestogether.5. Tightenthenuts.Replace the Flexible Scrapers1. Replacetheflexiblescrapersiftheflexiblescrapers are excessivelyworn or the scrapersaredamaged.2. Loosen the bolts and the nuts (1) that are holdingthe flexiblescraper(3).3. Remove the flexiblescraper (3). Install the newflexiblescraper.Note: Whenyou adjustthe scraper(3), thesteelbacking plates (2) must not come into contact withthe surfaceof the drum.4. Adjust the flexible scraper blades (2) to 7 mm(0.25 inch) away from the surface of the drum.The backing plates (2) must be set back 35 mm(1.375 inch) from the end of the scraper. Adjustthe scraper blades (3) and the backing platestogether.5. Tighten the bolts and tighten the nuts.Steel ScrapersThereisone scraperthatislocatedon thefrontbumper.96Maintenance SectionDrum Support Oil - ChangeAdjustLoosenthe two bolts.Adjust the steel scraper to 25 mm (1 inch) from thedrumsurface.Padded Drum Scraper Assembly (IfEquipped)Adjustg00480144Illustration 191There is one scraper that is located in front of thedrum.g00443301Illustration 192There is an optionalscraper that is located at therearof thedrum.1. Inspect the scraper. Clean the dirt and the debrisfromthescraper.2. Thereare two bolts (2) foreach scraper.Eachscraper is individually adjustable.3. Slidethe scraper towardthe drum. Adjust thetipssothetipsare25mm(1inch)fromthesurfaceof thedrum.4. Tightenbolts andthe nuts.i01323499Drum Support Oil - Change(CS-531D Machine Only)SMCS Code: 6605-044-OCS/N: AGH1-UpThe drum support is located on the left side of thedrum.g00700070Illustration 193Note: When the fill plug (1) is in the twelve oclockposition,the level check plug(2)isinthethreeoclock position. The drain plug (3) will be locatedat the six oclockposition.g00700087Illustration 1941. Rotate the drum until the drain plug (3) is locatedat the six oclockposition.2. Removethedrainplug(3).Draintheoil intoasuitablecontainer.Disposeof theoil inanacceptablemanner.3. Afterthe oil isdrained,cleanthe drainplug.Install the drainplug.4. The fill plug (1) is locatedat the twelve oclockposition.97Maintenance SectionDrum Support Oil - Check5. Removethe fill plug(1).6. Refer to the Operation and Maintenance Manual,Lubricant Viscosities and Refill Capacities.7. Fill the support until the oil is at the bottom of thefill plugopening.8. Cleanthe plug. Install the plug.9. Check the level of oil in the housing. Maintain thelevel of oil at the level check plug (2).i01323484Drum Support Oil - Check(CS-531D Machine Only)SMCS Code: 6605-535-FLVS/N: AGH1-UpThe drum support is located on the left side of thedrum.g00700070Illustration 195Note: When the fill plug (1) is in the twelve oclockposition,the level check plug(2)isinthethreeoclock position. Thedrain plug willbe locatedatthe six oclockposition.1. Remove the level check plug (2). Check the levelof the oil in the housing. Maintain the level of theoil at the bottom of the level check plug opening.2. If the oil level is low, remove the fill plug (1).3. Refer to the Operation and Maintenance Manual,Lubricant Viscosities and Refill Capacities. Fillthe support until the oil is at the bottom of thelevel plugopening.4. Clean fill plug (1) and install the plug.i01323456Drum Support Oil Sample -Obtain(CS-531D Machine Only)SMCS Code: 6605-008S/N: AGH1-UpThe drum support is located on the left side of thedrum.g00700065Illustration 196Refer totheCaterpillar MachineFluidsRecommendations, SEBU6250, SOS Oil Analysis.Refer to the Operation andMaintenance Manual,Sampling Interval and Location of Sampling Valvefor information on obtaining the oil sample from thedrumsupport.Note: After you obtain an oil sample, add oil in orderto maintain the properlevel.i01481043Eccentric Weight Housing Oil- ChangeSMCS Code: 6606-044-OCChange the Oil1. Take an oil sample from each eccentric weighthousing. There is one eccentric weight housingoneachsideof thedrum. Noflushingisnecessary,if the oil samplecleanliness ratingis equal orlower than ISO 23/21.The flushingprocedure should be performed if an oil samplecleanliness rating is higher than ISO 23/21.98Maintenance SectionEccentric Weight Housing Oil - Changeg00661120Illustration 1972. Rotate the drum until the welded itemis at thetop of the drum. The drain plug is at the bottomofthe housing.3. Place a suitable container under the drain plug.Removethedrainplug. Drainthehousingcompletely. Repeat this step for both housings.4. Cleanthe plug. Install the plug.5. Rotate the drum until the welded itemis at thebottomof thedrum.g00612461Illustration 1986. Removethe fillerplug.g00661118Illustration 1997. Removethe level check plug. Fillthe housingwith oil. Refer to the Operation and MaintenanceManual, Lubrication Viscosities and OperationandMaintenanceManual, Refill Capacities.Maintain the level of the oil to the bottom of thelevel checkopening.8. Clean the plugs. Install the plugs.9. Repeatthis procedureforthe other eccentricweighthousing.Flush the Housingg00661129Illustration 2001. Therearetwo eccentric weighthousings. Thehousings are on each side of the drum. Performthe following procedure on each housing.2. Drain the oil from the eccentric weight housings.99Maintenance SectionEccentric Weight Housing Oil - Changeg00411939Illustration 2013. Pump 151 L (40 US gal) of a suitable hydraulicoil into a 208 L (55 US gal) drum.g00684344Illustration 202(1) 8C-6875 Connector(2) 8B-5774 Reducer Bushing(3) 9U-6989 Head(4) 9U-6983 Filter Element(5) 6V-3965 Nipple Assembly(6) 8T-4834 Swivel Orifice Tee(7) 127-8781 Filter Cart(8) 2.4 m (8 ft) of 25 mm (1 inch) hose(9) 3B-6498 Elbow(10) 3L-7024 Street Elbow(11) 127-0593 Connector(12) 3B-7728 Elbow(13) 3B-7265 Pipe Nipple(14) 940 mm (37 inch) of 25 mm (1 inch) pipe4. Use the 127-8781 Transfer Cart Group in orderto flush the oil inthe 208 L(55 USgal) drum.Filter the oil for 30 minutes. The particle count ofthe clean oil must be a maximum of ISO 18/13.g00411939Illustration 2035. Raisethe machine.Thedrumandtiresmustnot beincontactwith the groundor the floor.Support the machine on stands.g00412139Illustration 2046. Start the engine. Release the parking brake androtatethe drum until the fill/drain plug is at thetop of the housing. Remove the plug. Install thevalve and fitting assembly that is appropriate foryourmachine.g00698763Illustration 205100Maintenance SectionEccentric Weight Housing Oil - Change7. Assemblethe126-7187Adapter(17)intothe male endof the 5R-3796 QuickCouplingAssembly (16). Install the adapter into the holefor the oil fill/drain plug. Assemble the 8T-0198SealConnector (15) onto the female end of thequick coupler. Attach the female end of the quickcoupler to the transfer cart suction hose in orderto drain the flushing oil from the housing.g00661111Illustration 2068. Rotate the drum until the fill/drain plug is at thebottom. Put a mark on the surface of the drum atthe top of the drum.The mark will help identifythe position of the fill/drain plug.g00412139Illustration 2079. Remove the level check plug. Connect the quickcoupler (16). Fill the housing with 22 L (6 US gal)gallons of clean oil. Install the plug.g00609614Illustration 20810. Runthe first flush cycle.a. Start the engine. Release the brake.b. Set the travel speed control to low speed. Inorderto rotatethedrum,movethepropelcontrol.c. Set the vibratory amplitude control to the lowposition.d. Turn on the vibratory system. Run the vibratorysystemfor 5 seconds. Turn off the vibratorysystem. Repeat the cycle for three minutes.Note: Foreachcycle, donotrunthevibratorysystemmore than 5seconds.e. Stop the drum. Position the drum in order todrainthe housings.11. Install the transfer cart. Pump the oil out of thehousings. Cycle the oil through the filter for 30minutes. Cycle the oil until the oil is cleaned toa rating of ISO 18/13 or better.12. Install the transfer cartto the housings. Pumpthe oil into the housings. For the second cycle,repeat steps 6 through 9. After the second cycle,takeanoil samplebeforefilteringthe oil.Nofurther flushingisnecessary,if theoil samplecleanlinessratingisequal or lowerthan ISO19/16.Anotherflushingis necessary, ifthe oilsamplecleanlinessratingishigherthan ISO19/16.13. When the flushing is complete, rotate the drumto theposition inorderto drainthe housings.Remove the valve and fitting assembly. Drain asmuch of the oil as possible.101Maintenance SectionEngine Air Filter Primary Element - Clean/Replace14. Rotatethedrumuntil thefill/drainplugisatthe top.Removethe level check plug. Fillthedrum to the correct level. Refer to the OperationandMaintenanceManual, Capacities(Refill). Refer to the Special Publication, SEBU6250,Lubrication Specifications.Note: The new oil must have a oil sample cleanlinessrating that is equal or lower than ISO 18/13.i01205999EngineAirFilter PrimaryElement - Clean/ReplaceSMCS Code: 1054-070-PY; 1054-510-PYNOTICEDo not clean the filter elements by bumping or tappingthem. Do not use filter elements with damaged pleats,gaskets or seals. Engine damage can result.Make sure the cleaned filter elements are completelydrybefore installing intothe filterhousing. Waterre-maining in the elements can cause false indications ofcontamination in Scheduled Oil Sampling test results.Thefilterelementscanbecleaned byusingthefollowingmethods:pressureairpressurewaterdetergent washingWhenyouusepressureair, themaximumairpressureis205kPa(30psi). Whenyouusepressurewater,themaximumwaterpressureis280kPa(40psi).g00038608Illustration 2091. When you clean the inside pleats and the outsidepleats, directthe airalong the pleats or directthe wateralong the pleats.Theelement can bewashed ina solutionthatconsistsof warmwaterandof nonsudsinghousehold detergent. Fully rinse the pleats. Allowthe filter to air dry completely.2. Inspectthe filterelementsafteryou cleanthefilterelements. Do not use a filter if the pleats,the gaskets or the seals are damaged.3. Coverthecleanfilterelements. Storetheelements ina clean, dry location.Replace the primary element after the primaryelement hasbeencleanedsixtimes. Alsoreplacetheprimaryelement if theprimaryelement has been in service for one year.Remove the Primary Elementg00647005Illustration 2101. Open the engine compartment.g00701248Illustration 2112. Open the air filterhousing.102Maintenance SectionEngine Air Filter Secondary Element - Replaceg00701249Illustration 2123. Remove the primary filter element.4. Reverse the steps in order to install the primaryfilterelement.i01206037Engine Air Filter SecondaryElement - ReplaceSMCS Code: 1054-510-SENOTICEAlways replace the secondary filter element. Never at-tempt to reuse it by cleaning.The secondary filter element should be replaced at thetime the primary element is serviced for the third time.The secondary filter element should also be replacedif the yellow piston in the filter element indicator entersthe red zone after installation of a clean primary ele-ment, or if the exhaust smoke is still black.g00647005Illustration 2131. Open the engine compartment.g00701248Illustration 2142. Remove the air cleaner housing cover.g00701249Illustration 2153. Removethe primary filterelement from the aircleanerhousing.g00701274Illustration 2164. Remove the secondary filter element.103Maintenance SectionEngine Air Filter Service Indicator - Inspectg00701275Illustration 2175. Cover the air inlet opening. Clean the inside ofthe aircleanerhousing.g00701276Illustration 2186. Inspect the gasket between the air inlet pipe andthe aircleanerhousing. Replace the gasket ifthe gasket isdamaged.7. Uncovertheairinletopening. Install anewsecondaryelement.8. Install the primary element and the aircleanerhousingcover.g00614451Illustration 2199. Reset the filter element indicator.10. Close the engine compartment.i01206104EngineAirFilterServiceIndicator - InspectSMCS Code: 7452-040g00647953Illustration 2201. Open the engine compartment access door.2. Starttheengine.3. Run the engine at high idle.g00614547Illustration 2214. If the yellow piston in the engine air filter serviceindicatorentersthe redzone,servicetheaircleaner.5. Stoptheengine.Note: See the Operation and Maintenance Manual,Engine Air Filter Primary Element - Clean/Replace.SeetheOperationandMaintenanceManual,Engine Air Filter Secondary Element - Replace.6. Close the engine compartment access door.104Maintenance SectionEngine Crankcase Breather - Cleani01206179Engine Crankcase Breather -CleanSMCS Code: 1317-070g00647005Illustration 2221. Open the engine compartment.g00416818Illustration 2232. Loosenthe hose clamp(2). Removethe hose(3) fromthebreather.3. Removebolt (1). Remove the breather (4) andtheO-ring seal.4. Washthe breather(4) incleannonflammablesolvent. Dry the breather (4) with pressure air.5. Install the O-ring seal. Install the clean breather.6. Tightenthebolt(1) toatorqueof 72Nm(51lbft).7. Install the hose (3) onto the breather (4). Tightenthehose clamp(2).8. Close the engine compartment.i01206205Engine Governor Oil SupplyScreen - Clean/Inspect/ReplaceSMCSCode: 1264-510-Z3; 1264-571-Z3;1278-510-Z3;1278-571-Z3g00647005Illustration 2241. Open the engine compartment.g00270086Illustration 2252. Place a suitable container under the oil supplytube. Removethe oil supply tube(1) fromthecylinderhead.3. Remove the fitting(3) and the seal (2) from thegovernorhousing.4. Use a 6 mm hexagon wrench in order to removethescreen(4).5. Wash the screen (4) in solvent in order to removeanydebris.6. Inspectthescreen(4)fordamage. Replacedamagedparts.7. Install thescreen(4).Allow clearanceforthefitting(3).105Maintenance SectionEngine Mounts - Inspect8. Install the seal (2). Install the fitting(3).Installthe oil supplytube(1).Note: Dispose of the fluids in an appropriate manner.9. Close the engine compartment.i01206214Engine Mounts - InspectSMCS Code: 1152-040g00647005Illustration 2261. Open the engine compartment.Therearefourenginemounts.Thereisoneengine mount at each corner of the engine.g00701246Illustration 2272. Enginevibrationcanbecausedbyimpropermounting of the engine. Engine vibration can becaused by loose engine mounts or deterioratedenginemounts.3. Inspecttheenginemountsfordeterioration.Replace any engine mount that is deteriorated.4. Inspect the engine mounts for correct bolt torque.5. Tighten the mounts if the mounts are loose.6. Close the engine compartment.i01206249Engine Oil Level - CheckSMCS Code: 1348-535-FLVNOTICEDo not under fill 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.1. Park the machine on a level surface.g00647953Illustration 2282. Open the engine compartment access door.g00614588Illustration 2293. Remove the dipstick (1). Wipe the dipstick withacleancloth.Insert the dipstick. Removethedipstick and note the oil level. Insert the dipstick.Note: RefertotheOperationandMaintenanceManual, Lubricant Viscosities and Refill Capacitiesfor the correctamount of oil that is used when theoil is changed. The correct amount of oil determinesthe correct level of the oil in the FULL range on thedipstick.106Maintenance SectionEngine Oil Sample - ObtainNOTICEDonot overfill thecrankcase.Theoil level mustnotreachthetopofthe FULL range mark orabove theFULL range mark.g00367841Illustration 2304. Maintain the oil level on the dipstick between theFULL 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 cause thecrankshaft to dipinto the oil.This couldresultinexcessively high operating temperatures. The highoperatingtemperaturescouldresultinreducedlubricatingcharacteristicsofthe oil. Thiscouldcause damage to the bearings and loss of enginepower.Add The Engine Oilg00647005Illustration 2311. Open the engine compartment.g00614596Illustration 2322. Removethe oil filler plug (2).3. Addtheoil.4. Clean the oil filler plug. Install the oil filler plug.5. Close the engine compartment.i01206334Engine Oil Sample - ObtainSMCS Code: 1348-008Hotoilandhotcomponentscancausepersonalinjury. Do not allow hot oil or hot components tocontact the skin.Obtain the Sample and the AnalysisInadditiontoagoodpreventivemaintenanceprogram, Caterpillarrecommends usingSOS oilanalysisatregularscheduledintervalsinordertomonitortheconditionoftheengineandthemaintenance requirementsof the engine.Each oil sampleshould betakenwhenthe oil iswarm andwhen the oil is well mixed. The sampleshouldbetakenatthistimeinordertoensurethatthe sample isrepresentativeof the oil inthecrankcase.Obtain the SOS SampleUse one of the following methods in order to obtainanSOSsample:Use the oil sampling valve (if equipped).Usea1U-5718VacuumPumpor useanequivalent pump that is inserted into the sump.107Maintenance SectionEngine Oil and Filter - ChangeCaterpillar recommendsusing the sampling valve(if equipped) inordertoobtainoil samples.Thequality and the consistency of the samples is betterwhen the sampling valve is used. If the engine isnot equipped with a sampling valve,the use of a1U-5718 Vacuum Pump is preferred.To avoid contamination of the oil samples, the toolsandthe suppliesthatareusedforobtainingoilsamples mustbeclean.Refer toCaterpillar MachineFluidsRecommendations, SEBU6250, LubricantSpecifications for more information on obtaining agood oil sample. Consult your Caterpillar dealer forcomplete information and assistance in establishingan SOS program for your engine.g00647005Illustration 2331. Open the engine compartment.g00701277Illustration 2342. The oil sampling valve is on the right side of theengine.The oil sampling valve is located nearthesteering pump.3. Open the sampling valve. Obtain an oil sampleina suitable container andclose the samplingvalve.4. Seal the container and label the container. Sendthe sample to your Caterpillar dealer for analysis.5. Close the engine compartment.i01206557Engine Oil and Filter - ChangeSMCS Code: 1318-510Run the engine inorderto warm upthe oil. Stopthe engine beforeyou drain the oil.When the oilis warm the waste particles are suspended in theoil. The wasteparticles willbe removed when theoil isdrained.Asthe oil cools, thewasteparticles settleto thebottom of the oil pan. The wasteparticles will notbe removed if the oil is too cool.Thewasteparticlescanrecirculatethroughtheenginelubricationsystemif therecommendedprocedureis not followed.g00647005Illustration 2351. Open the engine compartment.g00701278Illustration 2362. Place a suitable container under the drain valve.Openthe drain valve.3. Allow the oil to completely drain.108Maintenance SectionEngine Oil and Filter - Change4. Closethe drain valve.g00701279Illustration 2375. Remove the filter element. Discard the used filterelement.6. Clean the filter housing base. All of the old filterseal mustberemovedfromthe filterhousingbase.7. Apply a thin coat of engine oil to the seal of thenewfilterelement.8. Install the new filterby hand. When the gasketcontacts the filter base, turn the filter element foran additional three quarters of a turn. This willtighten the filtersufficiently.Rotation index marks are positioned on the filterat 90 degree intervals. Use theserotation indexmarks as a guide when you tighten the filter.g00614639Illustration 2389. Removetheoil fillerplug.Fill thecrankcasewith newoil.See Operation andMaintenanceManual, Refill Capacities. See Operation andMaintenanceManual, LubricantViscosities.Clean the oil filler cap and install the oil filler cap.g00614647Illustration 239g00367841Illustration 24010. Beforeyou start the engine, check the oil levelon the dipstick. The oil level must be within theFULL RANGE onthe dipstick.11. Start the engine. Run the engine for two minutes.Inspect the machine for leaks. Stop the machine.12. Wait fortenminutesinorderto allowtheoiltodrain backintothecrankcase.Checktheoil level. Maintainthe oil level withinthe FULLRANGEon the dipstick.13. Start the engine. Run the engine for two minutes.Inspect the machine for leaks. Stop the machine.14. Wait fortenminutesinorderto allowtheoiltodrain backintothecrankcase.Checktheoil level. Maintainthe oil level withinthe FULLRANGEon the dipstick.15. Close the engine compartment.109Maintenance SectionEngine Valve Lash and Injector Fuel Timing - Check/Adjusti01191256Engine Valve Lash and InjectorFuel Timing - Check/AdjustSMCS Code: 1105-025; 1105-535;1290-025-FT;1290-531-FTRefer to Systems Operation, Testing and Adjusting,SENR3583, Basic Engine Components 3114, 3116,& 3126 Engines for the correctprocedureswhenyou checkengine valve lashand/or injector FuelTiming.Note: Makesurethat qualifiedservice personnelcheckthe injectorFuel Timing.Ifanadjustmentisnecessary,makesurethat qualifiedservicepersonneladjust the injector Fuel Timing. Specialtools and trainingare required.Note: Thecorrect Fuel Timingspecificationisshown on the Engine Information Plate. Fuel timingspecificationswill bedifferent with eachengineapplication and with each power rating.Consultyour Caterpillardealerforthecompleteadjustmentprocedure.i01206694Engine Water Pump - InspectSMCS Code: 1361-040A water pump thathas failedmight cause severeengineoverheating.Severeengineoverheatingcould resultin the following problems:Cracks inthe cylinder headPistonseizureOther potential engine damageg00647005Illustration 241Open the engine compartment.The water pump is located on the engine blockatthe frontof theengine.g00701280Illustration 242Visually inspect the waterpump for leaks. If leaksare found, all the seals must be replaced.Note: See the Service Manual, KENR3520 for moreinformation.Close the engine compartment.i01323128Ether Starting Aid Cylinder -ReplaceSMCS Code: 1456-510-CD1. Open the engine compartment on the left side ofthemachine.g00699911Illustration 243110Maintenance SectionFinal Drive Planetary (Axle) Oil - Changeg00101321Illustration 2442. Loosenthe cylinder retainingclamp. Unscrewthe empty ether starting aid cylinder and removethe empty ether starting aid cylinder.g00104888Illustration 2453. Remove the used gasket. Install the new gasketthat is provided with each new ether starting aidcylinder.4. Install the new ether starting aid cylinder. Tightenthe ether starting aid cylinder by hand. Tightenthe cylinder retaining clamp securely.5. Close the engine compartment.i01484014Final Drive Planetary (Axle) Oil- ChangeSMCS Code: 4050-044-OCg00772126Illustration 246This photo was taken from below the machine.1. Removedrain plug (2).2. Drain the oil into a suitable container.3. Clean the drain plug, and install the drain plug.4. Remove level check/fill plug (1).5. Add oil to the planetary. Fill the planetary to thebottom of the level check/fill plug opening.6. Refer to the Operation and Maintenance Manual,Capacities (Refill), and Lubrication Viscosities.7. Clean the level check/fill plug and install the levelcheck/fill plug.Note: The oil in the final drive planetary is commontotheoil intheaxle. Theoil inthefinal driveplanetaryandtheaxleshouldbedrainedandrefilledseparately.111Maintenance SectionFinal Drive Planetary (Axle) Oil Level - Checki01484020Final Drive Planetary (Axle) OilLevel - CheckSMCS Code: 4050-535-FLVg00772131Illustration 247This photo was taken from below the machine.1. Inordertocheckthelevel oftheoil intheplanetary,removethe level check/fillplug(1).Maintain the level of the oil to the bottom of thelevel check/fillplug opening.2. Ifnecessary, addoil.3. Clean the level check/fill plug and install the levelcheck/fill plug.4. Refer to the Operation and Maintenance Manual,Capacities (Refill), and Lubrication Viscosities.i01484023Final Drive Planetary (Axle) OilSample - ObtainSMCS Code: 4050-008g00772136Illustration 248This photo was taken from below the machine.Obtain the oil sample when you change the oil.RefertotheSpecial Publication, SEBU6250,SOSOilAnalysis.Referto the OperationandMaintenanceManual, SamplingInterval andLocationofSamplingValveforinformationonobtaining the oil sample from the gearbox.i01431193Final Drive Planetary (Drum)Oil - Change(CS/CP-533D Machines Only)SMCS Code: 4050-044-OC; 5655-044-OCS/N: AFC1-UpS/N: AET1-Upg00612161Illustration 249The final drive planetary is located on the left sideofthedrum.1. Thedrainplugislocatedat thesixoclockposition.2. Removethedrainplug.Draintheoil intoasuitablecontainer.Disposeof theoil inanacceptablemanner.3. Afterthe oil isdrained,cleanthe drainplug.Install the drainplug.4. Thefillerplug(1)is locatedat the topofthegearbox. The level check plug (2) is located atthemiddle.5. Removethe filler plug (1) andthe level checkplug(2).6. Refer to the Operation and Maintenance Manual,Lubricant Viscosities and Refill Capacities.7. Fillthe planetary until the oil is at the bottom ofthe level check plug opening (2).112Maintenance SectionFinal Drive Planetary (Drum) Oil - Check8. Clean the plugs (1) and (2). Install the plugs (1)and(2).i01431199Final Drive Planetary (Drum)Oil - Check(CS/CP-533D Machines Only)SMCS Code: 4050-535-FLV; 5655-535-FLVS/N: AFC1-UpS/N: AET1-Upg00646901Illustration 250The final drive planetary is located on the left sideofthedrum.g00612161Illustration 2511. Plug (2) is located at the 90 degree position.2. Remove the level check plug (2). Check the levelof the oil in the gearbox. Maintain the level of theoil at the bottom of the level check plug opening.3. If the oil level is low, remove the fill/drain plug (1).4. In order to maintain the proper oil level, add oil.5. Clean the plugs and install the plugs.i01431219Final Drive Planetary (Drum)Oil Sample - Obtain(CS/CP-533D Machines Only)SMCS Code: 4050-008; 5655-008S/N: AFC1-UpS/N: AET1-Upg00660237Illustration 252Obtain the oil sample accordingto the OperationandMaintenanceManual, MaintenanceIntervalSchedule.RefertotheSpecial Publication, SEBU6250,SOSOil AnalysisandrefertotheOperationandMaintenance Manual, SamplingInterval andLocation of Sampling Valve for more information.i01206871Fuel System - PrimeSMCS Code: 1250-548g00647005Illustration 2531. Open the engine compartment.113Maintenance SectionFuel System Primary Filter - Clean/Inspect/Replaceg00480343Illustration 254g00418378Illustration 2552. Open the valve (1). Push the plunger (2) until thefuel starts to come out of the valve.3. Closethe valve(1).4. Push the plunger (2) for 10 additional strokes.5. Start the engine. Check for leaks.6. Close the engine compartment.Note: If the engine idle is rough, continue pushingplunger (2) until the engine idle is smooth.i01600179Fuel System Primary Filter -Clean/Inspect/ReplaceSMCS Code: 1260-040; 1260-070; 1260-510g00647005Illustration 2561. Open the engine compartment.g00614769Illustration 2572. Turn valve(1) in acounterclockwise direction.Drain the fuel into a suitable container.Note: Dispose of the waste in a proper manner.3. Closevalve(1).4. Hold bowl (5) while you loosen collar (4). Removebowl(5) andcollar(5).114Maintenance SectionFuel System Secondary Filter - Replaceg00372835Illustration 2585. Loosen collar (2). Remove element (3). Discardthe element in a propermanner.6. Cleanthe parts. Inspect the parts for damage.Replace the damaged parts or replace the wornparts.7. Install a new element. Tighten collar (2).8. Install bowl (5) and tighten collar (4).9. Start the engine and check the fuel system forleaks.10. Close the engine compartment.i01207283Fuel System Secondary Filter -ReplaceSMCS Code: 1261-510-SEPersonal injury can result from air pressure.Personal injury can result without following prop-er procedure. When using pressure air, wear a pro-tective face shield and protective clothing.Maximum air pressure at the nozzle must be lessthan 205 kPa (30 psi) for cleaning purposes.Personal injury can result when using cleaner sol-vents.To help prevent personal injury, follow the instruc-tions and warnings on the cleaner solvent contain-er before using.Personal injury or death can result from a fire.Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.Clean up all leaked or spilled fuel. Do not smokewhile working on the fuel system.Turn the disconnect switch OFF or disconnect thebattery when changing fuel filters.NOTICEDo notfill fuel filters withfuel beforeinstalling them.Contaminated fuel will cause accelerated wear to fuelsystem parts.115Maintenance SectionFuel System Secondary Filter - Replaceg00647005Illustration 2591. Open the engine compartment.g00480344Illustration 260Note: This machine is equipped with two secondaryspin-onfiltersonasingle filterbase. Theuppersecondary filterelement isupside-down. Alwaysdrain the inverted secondary filter element beforeyouremovethelowersecondaryfilterelementor beforeyouremovethe uppersecondary filterelement.2. Drain upper secondary filter element (1) (invertedfilter). Place a suitable container under the drainvalves(2) and(4).Opendrain valve(2) first.Then, immediately open drain valve (4).Drainthe fuel into a suitable container. When the fuelstopsdraining,keepthedrainvalvesopen.Loosentheinverted secondaryfilterelementfor1/4 turn. Asthe secondaryfilter element isloosened, additional fuel may drain from the drainvalves. When the fuel stops draining, loosen thesecondaryfilterelement foranadditional 1/4turn. Observethe flow of the fuel.Repeat thisprocedure until fuel does not drain from the drainvalves. Close the drain valves. Properly disposeofthefuel.Note: Make sure that the drain valves are opened inthe proper order. If you open the wrong drain valvefirst, an air lock in the fuel system may occur. Thiswill not allow fuel to drain from the upper secondaryfilterelement.3. Remove upper secondary filter element (1).4. Cleanthe filtermounting base. Make sure thatthe old seal is removed.5. Coat the seal of the new filter with cleandieselfuel.Note: Theuppersecondaryfuel filterelementandthelowersecondaryfuel filterelementaredifferent part numbers. Refer to the Operation andMaintenance Manual, Maintenance Parts List.6. Install new upper secondary filterelement (1).Hand tighten the upper secondary filter element.Whenthe seal contactsthe base,tightentheupper secondary filter element for an additional3/4turn.Rotation index marks are positioned on the filterat 90 degree intervals. Use theserotation indexmarks as a guide when you tighten the filter.Note: Install a new, dry filter.Never fill a new filterwith fuel before you install the filter.Dirty fuel candamage the fuel injectors. This damage willcauseprematureproblems in the fuel system.7. Remove lower secondary filter element (3).Note: Lowersecondary filterelement (3) hasnotbeen drained.Thefiltercontainsfuel.When youremove the lower filter, use caution in order to avoidspillingthefuel.8. Cleanthe filtermounting base. Make sure thatthe old seal is removed.9. Coat the seal of the new filter with cleandieselfuel.10. Install new lowersecondary filterelement (3).Hand tighten the lower secondary filter element.Whenthe seal contactsthe base,tightenthelower secondary filter element for an additional3/4turn.Note: Install a new, dry filter.Never fill a new filterwith fuel before you install the filter.Dirty fuel candamage the fuel injectors. This damage willcauseprematureproblems in the fuel system.11. Primethe fuel system. Seethe Operation andMaintenance Manual, Fuel System - Prime.116Maintenance SectionFuel System Water Separator - Drain12. Start the engine and check for leaks.13. Close the engine compartment.i01207305Fuel System Water Separator- DrainSMCS Code: 1263-543g00647005Illustration 2611. Open the engine compartment.g00614769Illustration 2622. Inordertoopen thedrain valve(1),turnthevalve in a counterclockwise direction. Allow thewaterto completely drain.3. Drainthewaterandsediment intoasuitablecontainer.Note: Dispose of the waste in a proper manner.4. Closethe drain valve(1).5. Close the engine compartment.i01207318Fuel System Water SeparatorElement - Replace(Fuel System Primary FilterElement)SMCS Code: 1263-510-FQg00647005Illustration 2631. Open the engine compartment.g00614769Illustration 2642. Turn the valve (1) in a counterclockwise direction.Drain the fuel into a suitable container.Note: Dispose of the waste in a proper manner.3. Closethe valve(1).4. Hold the bowl (5) while you loosen the collar (4).Remove the bowl (5) and the collar (5).117Maintenance SectionFuel Tank Breather - Replaceg00372835Illustration 2655. Loosen the collar (2). Removethe element (3).Discard the element in a proper manner.6. Cleanthe parts. Inspect the parts for damage.Replace the damaged parts or replace the wornparts.7. Install a new element. Tighten the collar (2).8. Install the bowl (5) and tighten the collar (4).9. Start the engine and check the fuel system forleaks.10. Close the engine compartment.i01207402Fuel Tank Breather - ReplaceSMCS Code: 1273-510-BREg00646559Illustration 2661. Open the engine compartment.g00614171Illustration 2672. The fuel tank breather is located behind the fueltankcap. Remove the breather.3. Install the newbreather.4. Close the engine compartment.118Maintenance SectionFuel Tank Cap and Strainer - Cleani01207409Fuel Tank Cap and Strainer -CleanSMCS Code: 1273-070-Z2; 1273-070-STRg00647005Illustration 2681. Open the engine compartment.g00614816Illustration 2692. Removefuel tankcap (1).g00614815Illustration 2703. Removefiller screen(2).4. Washfillerscreen(2) inclean, nonflammablesolvent. Dry the filler screen with pressure air.5. Inspectcap(1) andfiller screen(2).Replacethe cap if the cap is damaged. Replace the fillerscreen if the filler screen is damaged.6. Install fillerscreen (2).7. Apply a thin film of fuel to the gasket of the fueltankcap.8. Install fuel tankcap(1).9. Close the engine compartment.i01207435Fuel Tank Water and Sediment- DrainSMCS Code: 1273-543-M&Sg00648307Illustration 271This is the location of the fuel tank.g00612764Illustration 2721. Removethe access plate.119Maintenance SectionFuses - Replaceg00612826Illustration 2732. The drain valve is located on the bottom of thefuel tank. Drain the water and the sediment intoasuitablecontainer.3. Close the drain valve. Install the access plate.Note: Disposeof all fluidsaccordingtolocalregulations.i01156965Fuses - ReplaceSMCS Code: 1417-510Fuse Thefusesprotectthe electricalsystemfromdamagethatis causedbyoverloaded circuits. Change the fuse if theelement separates. If the element of the new fuseseparates,check the circuit.Repair the problembefore you operate the machine.g00615535Illustration 274Thecompartment forthe fuses islocatedon theright side of the machine. There are four screws thathold the cover on the compartment.In orderto access the compartment forthe fuses,remove the four screws. Remove the cover.g00615027Illustration 275(1) Dome Light(2) CompactionMeter(3) IgnitionSystem(4) Horng00615516Illustration 276(5) Thermal Starting Aid(6) Backup Alarm(7) Front Work Lights(8) Gauge Lights120Maintenance SectionHydraulic System Oil - Changeg00615520Illustration 277(9) Circulating Fan(10) Vibratory System(11) Rear Work Lights(12) Parking Brake(13) HoodActuator(14) Front Windshield Wiper/Washer(14) Rear Windshield Wiper/Washeri01204316Hydraulic System Oil - ChangeSMCS Code: 5050-044; 5056-044; 5095-044NOTICETake 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 maximumper-formance.g00647005Illustration 2781. Open the engine compartment.g00615109Illustration 279g00615121Illustration 2802. Removethehydraulictankcap(1)andthescreen(2).3. Wash the hydraulic tank capand the screen inclean, nonflammable solvent.4. Install thescreen.121Maintenance SectionHydraulic System Oil Filter - Replaceg00615204Illustration 2815. Connect ahose to the hydraulic oil tank drainvalve. The drain valve is located on the bottomof the hydraulic oil tank.Note:Thehydraulicoil tankcontains80L(21.1 USgal) of hydraulic oil.Drain the oil intoasuitablecontainer.Disposeoftheusedoil inapropermanner.6. Close the hydraulic oil tank drain valve. Removethehose.g00701283Illustration 2827. Disconnect the two hoses.8. Remove the two strainers. Clean the strainers ina nonflammable solvent.Dry the strainers withpressureair.9. Install the two strainers.10. Refill thehydraulictankwithclean, filteredhydraulicoil. RefertotheOperationandMaintenanceManual,Refill CapacitiesandLubricantViscosities.11. Add the oil through the filler tube. Clean the capandinstall thecap.g00615167Illustration 28312. Maintainthe oil level atthe level markonthedecal. The decal is beside the sight gauge.i01204359Hydraulic System Oil Filter -ReplaceSMCS Code: 5068-510g00648321Illustration 284g00648331Illustration 2851. Open the engine compartment.122Maintenance SectionHydraulic System Oil Level - Check2. Therearetwo filters. There isone filterontheright side of the machine, and there is one filteronthe left sideof the machine. Thefilters arelocated near the front of the machine. The filtersare located behind the frame. The propel filter (1)is on the right side of the machine. The vibratoryfilter (2) is on the left side of the machine.3. Inordertocatchanyoil thatspills, placeasuitable container under the filters.4. Remove the two filterelements. Clean the filterbases. Discard the filters in a proper manner.5. Coat the gasket of new filters with clean oil.6. Install the new filter elements. Hand tighten theelements.Whenthe gasket contactsthe filterbase,turnthefilterelement foranadditionalthree quarters of a turn. This will tighten the filtersufficiently.Rotation index marks are positioned on the filterat 90 degree intervals. Use theserotation indexmarks as a guide when you tighten the filter.g00615167Illustration 2867. Start the engine. Allow the hydraulic oil to warm.Maintain the oil to the level markon the decalthat is near the sight gauge. If necessary, add oil.Refer to the Operation and Maintenance Manual,Refill Capacities. Refer to the Operation andMaintenance Manual, Lubricant Viscosities.8. Close the engine compartment.i01204414Hydraulic System Oil Level -CheckSMCS Code: 5056-535-FLV; 5095-535-FLVg00647005Illustration 2871. Open the engine compartment.g00615167Illustration 2882. Observe the level of the hydraulic oil in the sightgauge when the oil is warm. Maintain the oil levelto the mark onthe sight gauge.3. Ifnecessary, addoil.Refer to the Operation and Maintenance Manual,Refill Capacities. Refer to the Operation andMaintenance Manual, Lubricant Viscosities..123Maintenance SectionHydraulic System Oil Sample - Obtaing00615109Illustration 2894. In order to add the oil, remove the filler cap (1).Add the oil through the filler tube. Clean the oilfiller cap andinstall the filler cap.5. Close the engine compartment.i01450883Hydraulic System Oil Sample- ObtainSMCS Code: 5050-008; 5095-008g00659521Illustration 290Theportislocatedbehindtheframenearthepropel filter.RefertotheSpecial Publication, SEBU6250,SOSOil AnalysisandrefertotheOperationandMaintenance Manual, SamplingInterval andLocation of Sampling Valve for more information.i01204032Hydraulic Tank Strainer - CleanSMCS Code: 5056-070-STRg00647005Illustration 2911. Open the engine compartment.g00615109Illustration 292g00615121Illustration 2932. Remove the hydraulic oil filler cap(1) and pullthe screen(2) outward.3. Clean the screen in clean, nonflammable solvent.Dry the screen with pressure air.124Maintenance SectionHydraulic Tank Vent - Replace4. Install the screen and install the cap.5. Close the engine compartment.i01606289Hydraulic Tank Vent - ReplaceSMCS Code: 5056-510-BRE; 5118-510g00647005Illustration 2941. Open the engine compartment.g00615138Illustration 2952. The ventis located onthe top of the hydraulictank.3. Remove the vent from the hydraulic tank.4. Wash the vent in clean, nonflammable solvent.5. Use pressure air to dry the vent. Air should beblown freelythrough the vent.Note: Theventshould bereplacedifthereisarestriction.6. Install the vent.7. Close the engine compartment.i01204262Indicators and Gauges - TestSMCS Code: 7450-081g00661742Illustration 296g00661734Illustration 2971. Look forbroken lenses on the gauges,brokenindicatorlights, brokenswitches,andotherbrokencomponents in the cab.2. Starttheengine.3. Look forinoperative gauges.4. Turnonall machinelights.Checkforproperoperation.5. Stoptheengine.Note: When the engine is stopped and the enginestart switchkey isturned to theONposition, allfour of the indicator lights should illuminate. If theindicator lights do not illuminate, repair the lights orreplacethe lights.6. Makeanyrepairsthat arerequiredbeforeoperating the machine.125Maintenance SectionLeveling Blade - Lubricatei01207667Leveling Blade - LubricateSMCS Code: 5102-086; 5103-086; 6060-086Note: Cleanthe fittingsbeforeyoulubricatethefittings.g00697185Illustration 298Lubricate the grease fitting that is located at the topof the leveling blade cylinder.g00697189Illustration 299Lubricatethe greasefittingthatis locatedat thebottom of the leveling blade cylinder.g00646200Illustration 300There are two grease fittings for the blade pivot pinsthat must belubricated. The fittings are located atthe bottom of the pivot. There is one fitting on eachsideof themachine.i01237030Neutral Start Switch - TestSMCS Code: 1424-025; 1424-081; 1424-535The machine may lurch forward if the neutral startswitchisoutofadjustment. Besuretheareaisclear ofallpersonneland equipment beforeper-forming this test.g00609614Illustration 3011. Place the propel lever in the FORWARD position.g00659490Illustration 3022. HoldtheenginestartswitchintheSTARTposition.Slowly movethe propel levertowardtheSTOP position.126Maintenance SectionOil Filter - Inspect3. If the engine starts before you move the propellevertotheSTOPposition, theneutral startswitch requires adjustment. Do not operate themachineuntil therepairshavebeenmade.Consult your Caterpillar dealer for instructions.i01479169Oil Filter - InspectSMCS Code: 1308-507; 3004-507; 3067-507;5068-507Inspect A Used Filter for Debrisg00100013Illustration 303The element is shown with debris.Use a4C-5084Filter Cutterora 175-7546OilFilter Cutter to cut the filterelement open. Spreadapart the pleats and inspect the element for metaland for other debris. An excessive amount of debrisin the filter element can indicate a possible failure.If metals are found inthe filterelement, a magnetcan be used to differentiate between ferrous metalsandnonferrousmetals.Ferrous metals can indicate wear on steel parts andoncastironparts.Nonferrousmetalscanindicatewear onthealuminumpartsof theenginesuchasmainbearings, rod bearings, or turbocharger bearings.Small amounts of debris maybe found in the filterelement. This could becaused by friction and bynormal wear.ConsultyourCaterpillardealerinorder to arrange for further analysis if an excessiveamountof 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.i01186107Radiator Core - CleanSMCS Code: 1353-070-KOg00647005Illustration 3041. Open the engine compartment.2. Theradiator coreislocatedat the rearof themachine.3. Inspect the radiator core for debris. If necessary,cleantheradiator.Compressed air is preferred,but high pressurewater of steam can be used to remove dust andgeneral debris from a radiator. Clean the radiatoraccording to the condition of the radiator.See Special Publication, SEBD0518, Know YourCoolingSystemformoreinformationaboutcleaningradiator fins.4. Close the engine compartment.127Maintenance SectionRollover Protective Structure (ROPS) - Inspecti01186077Rollover Protective Structure(ROPS) - InspectSMCS Code: 7323-040; 7325-040g00648616Illustration 305Inspect the rollover protective structure (ROPS) foranylooseboltsordamagedbolts.Replacethedamaged bolts with original equipment parts only.Replace the ROPS mounting support if the ROPSrattles. Replace the ROPS mounting support if theROPS makesnoise.Do not straighten the ROPS or repair the ROPS bywelding reinforcement plates to the ROPS.Consult your Caterpillar dealer for the repair of theROPS.i01431358Seat Belt - ReplaceSMCS Code: 7327-510; 7327g00645325Illustration 306Always check the condition of the seat belt. Alwayschecktheconditionofthemountinghardware.The checks must bedone before you operate themachine.You must replace the seat belt once during a threeyear period. The belt must be replaced regardlessof any damage. A date label is attached to the belt.The date label will determine the age of the belt.Inspectthebeltforwornwebbingorforfrayedwebbing.Check forworn bucklesoneach halfof the seatbelt. Check for damaged buckles on eachhalf ofthe seatbelt. Replace the seat belt or replace thebuckles if the belt or the buckles are damaged.g00646088Illustration 307Inspect the belt mounting hardware.Replace anyworn hardwareordamaged hardware.Keepthemountingbolts tight.i01186049SteeringCylinderEnds-LubricateSMCS Code: 4303-086-BDg00606848Illustration 308128Maintenance SectionTilt Hood Actuator - LubricateLower the steering frame lock pin into the lockedposition.Note: Wipe all of the fittingsbeforeyou lubricatethefittings.g00612954Illustration 3091. There are two steering cylinders, one on the rightside of the machine and one on the left side ofthe machine. Lubricatethe frontlube fitting(1)on eachside of the machine.g00612986Illustration 3102. Both the lubrication fittings for the rear end of thesteering cylinders are located on the left side ofthe machine. Lubricate the fittings (2) for the rearendof the steering cylinders.3. Raisethesteeringframelockpinintotheunlockedposition.i01186008Tilt Hood Actuator - LubricateSMCS Code: 7251-086-AQWipe all the grease fittings before lubricating.g00650603Illustration 3111. Raise the engine hood. The tilt hood actuator islocated on the right side of the machine.2. Fullyextend the cylinder andgreasethe innerpost (2).Greasethe entirelength ofthe innerpost.g00650609Illustration 3123. Lubricate the two fittings (3) on the cylinder.4. Closethe engine hood.Lubricate The Hoodg00615322Illustration 313129Maintenance SectionTire Inflation - CheckThere are two lubrication points for the hood. Onelubrication point is on the right side of the hood andone lubrication point is on the left side of the hood.Lubricate both sides of the hood.i01185963Tire Inflation - CheckSMCS Code: 4203-535-PXg00648663Illustration 314If necessary, inflate the tires.For normal operating conditions, inflate the tires tothe properpressure:The proper pressure for the CS-531D is 110 kPa(16psi).The proper pressure for the CS-533D is 110 kPa(16psi).The proper pressurefor the CP-533D is 83 kPa(12psi).The tire inflation pressure is based on the weight ofa machine that is ready to work and the machine iswithout attachments. The pressure is based on therated payload, and in average operating conditions.Pressuresforeach applicationmayvary.Consultyour Caterpillar dealer for more information aboutpropertire inflation pressures.i01207492Vibratory Support Oil - ChangeSMCS Code: 5656-044-OCg00648665Illustration 315The vibratory drive gearbox is located on the rightsideofthe drum.g00484487Illustration 3161. Removethe drain plug (3).Drain the oil into asuitablecontainer.Note: Dispose of the used oil in a proper manner.2. Cleanthedrain plug(3)andinstall the drainplug.3. Remove the oil level check plug (2).4. Removethe oil filler plug (1).5. Addthe oil throughtheoil filler plughole(1).Add the oil until the oil reaches the bottom of theopening for the oil level check plug.6. Refer to the Operation and Maintenance Manual,Lubricant Viscosities and Refill Capacities.130Maintenance SectionVibratory Support Oil Level - Check7. Clean the oil level check plug and install the oillevel check plug. Clean the filler plug and installthefillerplug.i01207510Vibratory Support Oil Level -CheckSMCS Code: 5656-535-FLVg00648665Illustration 317The vibratory drive gearbox is located on the rightsideofthe drum.g00484495Illustration 3181. Removethe level check plug (2).Maintain thelevel of the oil to the bottom of the level checkplugopening.2. If the oil level is low, remove the oil filler plug (1).3. Add oil in order to maintain the proper level.4. Clean the level check plug and install the levelcheck plug. Cleanthe filler plug and install thefillerplug.i01207565Vibratory Support Oil Sample- ObtainSMCS Code: 5656-008g00648665Illustration 319Obtain the oil sample when you change the oil.Refer totheCaterpillar MachineFluidsRecommendations, SEBU6250, LubricantSpecifications. Refer totheOperationandMaintenanceManual, SamplingInterval andLocationofSamplingValveforinformationonobtaining the oil sample from the vibratory support.Note: After you obtain an oil sample, add oil in orderto maintain the properlevel.i01207571Walk-Around InspectionSMCS Code: 1000-040; 7000-040NOTICEAccumulated grease or oil on a machine is a fire haz-ard. Remove this debris withsteam cleaning orhighpressure water at least every 1000 service hours or atany time there is a significant amount of oil spilled onthe machine.Note: Checkthemachineforleaks.Ifaleakisfound, findthe source of the leak. Repairthe leakbefore you start the machine. Check the fluid levelsmore frequently if you suspect a leak.131Maintenance SectionWheel Nuts - Tighteng00701287Illustration 320Checktheairfilterserviceindicator.Whentheindicator is red, service the air filter element.g00648667Illustration 321Inspect the lights for broken bulbs or broken lenses.Replace the bulbs or the lenses if the bulbs or thelensesarebroken.Remove any trash in the engine compartment.Inspectthecoolingsystemforleaks,damagedhoses, or trash. Repair any leaks. Remove any trashfromtheradiator.Inspect theengineattachmentsforwear ordamage. Replace any components that arewornordamaged.Inspectthehydraulic systemforleaks.Inspectthe following components: the hydraulic tank, thecylinder rodseals,the hoses,thelines, andthefittings.Repairanyleaks.Repairanydamagedcomponents or worn components.Inspect the rear axle for any leaks.Inspectthe tiresfordamage.Check thetiresforproper inflation. Replace missing valve caps.Make sure that all covers andguards are firmly inplace. Check the guards and covers for damage.Inspectthesteps, walkways,andhandholdsfordamageor wear.Check the steps, walkways andhandholdsforcleanliness.InspecttheRolloverProtective Structure (ROPS) for damage. If repair isnecessary, consult your Caterpillar dealer.Tightenanyloosebolts.Inspect the operator compartment for cleanliness.Keep the operator compartment clean.If equipped, adjust the rear view mirrors for the bestvision.g00701288Illustration 322Inspecttherubberisolationblocksfordamage,cracking,or splitting.i01237211Wheel Nuts - TightenSMCS Code: 4210-527g00660786Illustration 323Tighten the wheel nuts to a torque of 430 60 Nm(32044lbft).132Maintenance SectionWindow Washer Reservoir - Filli01179871Window Washer Reservoir - Fill(If Equipped)SMCS Code: 7306-544g00613568Illustration 324The window washer reservoir is located on the rightsideofthecab.g00613560Illustration 325If the level of the cleaning solution is low, refill thereservoir.i01179888WindowWiper -Inspect/Replace(If Equipped)SMCS Code: 7305-040; 7305-510g00697255Illustration 326Inspectthe frontwindshield wiperbladeand therear windshield wiper blade. If necessary, replacethe windshield wiperblades.i01317273Windows - Clean(If Equipped)SMCS Code: 7310-070Usecommerciallyavailablewindowcleaningsolutions in orderto clean the windows. Clean theoutside of the cab windows from the ground unlesshandholdsare available.