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MAINTENANCE INTERVALS - Safety

1. 134 Fuel System Water Separator Drain 134 Fuel Tank Water and Sediment Drain 135 Hydraulic System Oil Level Check 06 140 Push Plate Lubricate 0 0 cceesceeeeeeee ees 142 Radiator Core Clean ccssssssessseseseeeeeeeeeees 142 Seat Belt Inspect oo eee eeeeeseeeeeeseeeeeteeteneees 144 Transmission Oil Level Check cee 153 Transmission Oil Level Check c eee 154 Every 50 Service Hours or Weekly Bail Bearings and Push Plate Spring Lubricate 94 Bowl Lift Cylinder Bearings Lubricate 96 Cab Air Filter Clean Replace n se 101 Hitch Lubricate ano sesrineni ioraa 137 Tire Inflation Check cccccccceeeeteeeeeeeeteneeeeees 146 Every 250 Service Hours or Monthly Air Dryer Check ceecceeeeeeeeeeeeeeeeeeeneeeeeaeeeeeaeeee 92 Air Dryer Desiccant Replace ceee 92 Battery Clean Check cccecceeeeeeesetteeeeneeeeens 94 Belt Inspect Adjust Replace cccscccceesseees 95 Brake Air System Pressure Test cceeeseees 97 Braking System Test cccceeeeeeeeeeeeeteeeteneeeeees 99 Engine Oil High Speed and Oil Filter Change 122 Engine Oil High Speed and Oil Filter Change 123 Engine Oil Sample Obtain s 125 Engine Oil and Filter Change s e 126 Engine Oil and Filter Change sses 127 Fan Drive Bearing and Belt Tightener LUD iCa
2. Illustration 287 g00103206 3 Remove the sump drain plug and drain the oil into a suitable container 4 Change the filter element Refer to the Operation and Maintenance Manual Transmission Oil Filter and Magnetic Screen Replace Clean g00103205 Illustration 288 5 Remove the cover for the scavenge screen 6 Remove the scavenge screen from the housing 7 Wash the scavenge screen in a clean nonflammable solvent 8 Clean the cover for the scavenge screen and inspect the seal Replace the seal if damage or wear is evident 9 Insert the scavenge screen into the housing 10 Install the housing cover Tighten the bolts in the housing cover 11 Clean the transmission drain plug and install the transmission drain plug 12 Clean the sump drain plug and install the sump drain plug 149 Maintenance Section Transmission Oil Change Illustration 289 g00103211 13 Fill the transmission with oil through the filler tube Refer to the Operation and Maintenance Manual Capacities Refill and the Operation and Maintenance Manual Lubricant Viscosities g00103213 Illustration 290 14 Remove the transmission breather 15 Wash the transmission breather in a clean nonflammable solvent 16 Install the transmission breather 17 Start the engine Run the engine at low idle Inspect the transmission for leaks 18 Slowly operate the transmission direction and spe
3. g00874087 Illustration 234 2 Clean the area around the dust cover 2 for the male quick coupler that is on the hose Remove the dust cover Clean the male fitting 3 Remove the dust cover from female fitting of the suction hose Clean the female fitting Attach the suction hose to the male fitting Remove the oil from the engine 124 Maintenance Section Engine Oil Level Check Illustration 235 4 Remove the filter elements 3 with a strap type wrench Refer to Operation and Maintenance Manual Oil Filter Inspect 5 Clean the filter mounting base with a clean towel Make sure that the old filter gasket has been removed 6 Apply a thin film of clean engine oil to the sealing surface of the new filter element 7 Install the new filter elements hand tight When the gasket contacts the filter base turn the filter by 270 degrees more This will tighten the filter sufficiently 8 Every new oil filter has marks which are for determining the rotation index These marks are spaced at 90 degree increments Use the rotation index marks as a guide for tightening the oil filter 9 Pump new oil into the engine See the following topics e Operation and Maintenance Manual Lubricant Viscositites e Operation and Maintenance Manual Capacities Refill 10 Remove the hose from the male coupler Install the dust cover 11 Start the engine and allow the oil to warm Check the engine
4. 12 Start the engine and allow the oil to warm Check the engine for leaks Check the filter for leaks 13 Run the engine and check dipstick 2 after the engine has been running for ten minutes Maintain the oil between the marks on the SAFE OPERATING RANGE side of the dipstick If necessary add oil 14 Close the engine access door and stop the engine 101698411 Engine Oil and Filter Change SMCS Code 1318 510 S N 6PR1 Up S N 7KR1 Up Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 243 g00874372 The crankcase drain for the scraper engine is located on the oil pan of the engine at Illustration 244 g00874373 The oil filter 3 for the scraper is located on the right side of the engine Park the machine on a level surface and engage the parking brake Stop the engine
5. 8 Start the engine Operate the engine without the cooling system pressure cap until the water temperature regulator opens and the coolant level stabilizes 9 Maintain the coolant level at the bottom of the filler pipe so that the sight gauge is completely covered 10 Inspect the gasket of the cooling system pressure cap If the gasket is damaged replace the gasket 11 Install the cooling system pressure cap 12 Stop the engine 104 Maintenance Section Cooling System Coolant ELC Change 101922356 Cooling System Coolant ELC Change SMCS Code 1350 044 NL S N 6PR1 Up S N 7KR1 Up NOTICE Do not change the coolant until you read and under stand the cooling system information in Special Pub lication SEBU6250 Caterpillar Machine Fluids Rec ommendations Failure to do so could result in damage to the cooling system components NOTICE Mixing ELC with other products reduces the effective ness of the coolant and shortens coolant life Use on ly Caterpillar products or commercial products that have passed the Caterpillar EC 1 specifications for premixed or concentrate coolants Use only Caterpillar Extender with Caterpillar ELC Failure to follow these recommendations could result in the damage to cool ing systems components If ELC cooling system contamination occurs see the topic Extended Life Coolant ELC in the Special Pub lication SEBU6250 Caterpillar Machine Fluids Rec o
6. A WARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Your machine may be equipped with a high speed arrangement for changing the engine oil The high speed arrangement allows the oil to be quickly withdrawn The high speed arrangement allows the oil to be quickly replaced The high speed arrangement has a hose which is attached to the oil pan at the drain hole The other end of the hose has a quick coupler 1 Drain the crankcase while the oil is warm This allows waste particles that are suspended in the oil to drain As the oil cools the waste particles will settle to the bottom of the crankcase The particles will not be removed by draining the oil and the particles will recirculate in the engine lubrication system with the new oil Park the machine on a level surface Shut off the engine Apply the parking brake
7. 50 kPa 125 10 psi 2 Raise the bowl slightly 3 Apply the service brake and release the parking brake 4 While the service brake is applied move the transmission direction and speed control to second speed 5 Gradually increase the engine rom The service brake should prevent machine movement when the engine is running at 1500 100 rpm The engine rom should be 1500 100 rom or more Record the actual engine rpm that is achieved during the test for future comparisons If the engine rpm is less than 1400 rpm consult your Caterpillar Dealer for an inspection of the machine and for repairs for the machine 100 Maintenance Section Braking System Test 6 Reduce the engine speed to low idle and move the transmission direction and speed control to the NEUTRAL position Engage the parking brake Lower the bowl to the ground and stop the engine Note If the friction material for the brakes needs to be replaced the new friction material may require burnishing for maximum performance Consult your Caterpillar dealer for the procedure for burnishing Parking And Secondary Brake Holding Ability Test If the machine begins to move reduce the engine speed immediately and engage the parking brake NOTICE If the machine moved while testing the brakes contact your Caterpillar Dealer Have the dealer inspect and if necessary repair the service brakes before returning the machine to operation Make sure
8. i01360098 Engine Air Filter Service Indicator Screen Check Replace SMCS Code 7452 510 Z3 7452 535 Z3 Illustration 228 g00713605 Typical Example Check 1 Set an 8N 2694 Air Filter Service Indicator to indicate a restricted indicator screen 2 Screw the indicator onto a 1 8 inch NPT pipe nipple 3 Screw the other end of the nipple into the threaded hole in the elbow Normally filter screen 1 is located in the elbow 4 Depress the reset button on the 8N 2694 Air Filter Service Indicator 5 If the indicator resets filter screen 1 is not plugged If the indicator does not reset filter screen 1 is plugged Filter screen 1 should then be replaced Replace 1 Remove the air cleaner from the air cleaner housing Removing the air cleaner from the air cleaner housing will provide access to the hole inside the elbow Filter screen 1 is installed inside the elbow 2 A 2 inch piece of 1 8 inch drill rod is needed in order to push filter screen 1 from the inside of the elbow to the outside 3 After the plugged filter screen 1 has been removed install a new filter screen 1 in the hole on the outside of the elbow Use a piece of 1 4 inch drill rod to lightly seat the filter element in the bottom of the bore 101550089 Engine Air Precleaner Clean SMCS Code 1055 070 NOTICE Service the engine air precleaner only with the engine stopped Engine damage could result The engi
9. Always check the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine Replace any parts that are damaged or worn before you operate the machine 101866630 Seat Belt Replace SMCS Code 7327 510 S N 5YR1 Up S N 6TR1 Up Within three years of the date of installation 2 or within five years of the date of manufacture 1 replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to each seat belt Illustration 278 g00932801 Typical example Check the seat belt mounting hardware 1 for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight Check buckle 2 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect the seat belt 3 for webbing that is worn or frayed Replace the seat belt if the seat belt is worn or frayed Contact your Caterpillar dealer for the replacement of the seat belt and mounting hardware Note Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to each seat belt g00951532 Illustration 279 1 Date of Manufacture 2 Date of Installation Contact your Caterpi
10. S O S Oil Analysis for information that pertains to obtaining a sample of the engine oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the engine oil 126 Maintenance Section Engine Oil and Filter Change 101698376 Engine Oil and Filter Change SMCS Code 1318 510 S N 5YR1 Up S N 6TR1 Up Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates g00102391 Illustration 240 The oil drain for the tractor engine is located on the engine oil pan A guard covers the oil pan Illustration 241 g00874354 The oil filter 3 for the tractor is on the right side of the engine Note Drain the crankcase while the oil is warm This allows waste particles that are suspended in the oil to drain As the oil cools the waste particles
11. continue with Step 6 6 Prime the fuel injector nozzle by first opening the fuel inlet line The fuel injector nozzle must be held in order to open the fuel line The line may need to be wiggled slightly in order to allow the fuel to flow from the line 7 Continue to prime the fuel system until the flow of fuel from the line is free of air bubble s Close the line Follow this procedure for all of the injectors 8 Continue pumping the knob The fuel system is primed when resistance is felt in the system 9 Push in on the knob for the pump Turn the knob clockwise in order to lock the knob 10 Start the engine If the engine will not start further priming is necessary If the engine starts but the engine continues to misfire further priming is necessary If the engine starts but the engine continues to emit smoke further priming is necessary 11 If the engine starts but the engine runs rough continue to run the engine at low idle Continue to run the engine at low idle until the engine runs smoothly 101699573 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE S N 5YR1 Up S N 6TR1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to S
12. 070 g00104395 Illustration 274 The hydraulic tank breaker relief valve is located on the top of the hydraulic tank at the rear of the tractor 1 Remove the breaker relief valve slowly in order to relieve the pressure 2 Wash the breaker relief valve in a clean nonflammable solvent 3 Shake the breaker relief valve until the breaker relief valve is dry You may also use pressure air to dry the breaker relief valve 4 Inspect the breaker relief valve and inspect the O ring seal Replace any of these components if necessary 5 Install the breaker relief valve 101719384 Oil Filter Inspect SMCS Code 1308 507 3004 507 3067 507 5068 507 Inspect a Used Filter for Debris Illustration 275 g00100013 The element is shown with debris Use a 40 5084 Filter Cutter or a 175 7546 Oil Filter Cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can indicate a possible failure If metals are found in the filter element a magnet can be used to differentiate between ferrous metals and nonferrous metals Ferrous metals can indicate wear on steel parts and on cast iron parts 142 Maintenance Section Push Plate Lubricate Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings rod bearings or turbocharger bearings Small amounts of debris m
13. 13 Shut off the engine 101863872 Tire Inflation Check SMCS Code 4203 535 Al Illustration 283 g00103147 Measure the pressure on each tire Consult your tire dealer for the correct load rating and for the correct operating pressures If necessary inflate the tires Refer to the following additional information about tire inflation e Operation and Maintenance Manual Tire Inflation with Nitrogen e Operation and Maintenance Manual Tire Shipping Pressure e Operation and Maintenance Manual Tire Inflation Pressure Adjustment 147 Maintenance Section Transmission Breather Clean e Operation and Maintenance Manual Tire Information i01700144 Transmission Breather Clean SMCS Code 3030 070 BRE S N 5YR1 Up S N 6TR1 Up g00103213 Illustration 284 The transmission breather for the tractor is located on the top of the transmission and at the right rear of the tractor Use the following procedure to clean the breather 1 Clean the area around the breather 2 Remove the breather 3 Wash the breather in clean nonflammable solvent 4 Allow the breather to dry 5 Install the breather i01703906 Transmission Breather Clean SMCS Code 3030 070 BRE S N 6PR1 Up S N 7KR1 Up g00877251 Illustration 285 The transmission breather for the scraper is located at the rear of the scraper Use the following procedure to clean the breather 1 Clea
14. Check the operation of the service indicator by pressing reset button 1 on the bottom of the service indicator This should require three pushes or less of the reset button 3 Next check the movement of the yellow piston in the service indicator Start the engine and accelerate the engine to high idle for a few seconds After the accelerator control pedal is released the yellow piston should remain at the highest position that was achieved during acceleration Note The air filter indicator should be replaced during engine overhauls The air filter indicator should also be replaced during replacement of any major engine component Replace the air filter indicator at least one time per year 4 If the indicator will not reset easily replace the service indicator If the yellow piston of the indicator will not latch at the highest vacuum that is attained replace the service indicator Tighten the indicator to a torque of 2 N m 18 Ib in Excessive tightening force may crack the top of the indicator For more information on the air filter indicator refer to Video Tape PEVN1736 Caterpillar Air Filter Service Indicator 120 Maintenance Section Engine Air Filter Service Indicator Screen Check Replace Note If you still believe that the service indicator is working improperly refer to Operation and Maintenance Manual Engine Air Filter Service Indicator Screen Check Replace 5 Close the access door
15. Clean the drain plug and install the drain plug Tighten the drain plug to a torque of 68 7 Nim 50 5 Ib ft 8 Install the filler screen 9 Fill the hydraulic tank See Operation and Maintenance Manual Capacities Refill 10 Inspect the gasket for the oil filler cap If the gasket is damaged replace the gasket 11 Install the oil filler cap 12 Start the engine and run the engine for a few minutes g00102874 Illustration 267 13 Maintain the oil level above the ADD mark in the sight gauge Add oil if necessary Note The oil must be free from bubbles If there are bubbles in the oil then air is entering the hydraulic system Inspect the suction hoses and the clamps 14 Stop the engine If necessary tighten any loose clamps and any loose connections Replace any damaged hoses 139 Maintenance Section Hydraulic System Oil Filter Replace 101699854 Hydraulic System Oil Filter Replace SMCS Code 5068 510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar product
16. Maintenance Manual Capacities Refill Clean the oil filler cap and install the oil filler cap 12 Start the engine and allow the oil to warm Check the engine for leaks Check the filter for leaks 13 Run the engine and check the dipstick 5 after the engine has been running for ten minutes Maintain the oil between the marks on the SAFE OPERATING RANGE side of the dipstick If necessary add oil 101719360 Engine Transfer Gear Scavenge Screen Clean SMCS Code 1164 070 Z3 S N 5YR1 Up S N 6TR1 Up The scavenge screen is located under the rear of the engine Wipe all surfaces around the openings before removing any components g00104385 Illustration 246 1 Remove the drain plug 2 and allow the oil to drain into a suitable container Note Discard the drained fluids according to local regulations 2 Remove the bolts 1 and remove the scavenge screen 3 Wash the scavenge screen in a clean nonflammable solvent 4 Clean the drain plug 2 5 Install the drain plug 2 6 Install the scavenge screen Tighten the bolts 1 129 Maintenance Section Engine Valve Lash Check 101714628 Engine Valve Lash Check SMCS Code 1105 535 A WARNING Ensure that the engine can not be started while this maintenance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additiona
17. Note Discard the drained fluids according to local regulations 3 Change the filter element Refer to the Operation and Maintenance Manual Transmission Oil Filter and Magnetic Screen Replace Clean g00877466 Illustration 293 4 Remove the cover for the scavenge screen 5 Remove the scavenge screen from the housing 6 Wash the scavenge screen in a clean nonflammable solvent 7 Clean the cover for the scavenge screen and inspect the seal Replace the seal if damage or wear is evident 8 Insert the scavenge screen into the housing 9 Install the housing cover Tighten the bolts in the housing cover 10 Clean the transmission drain plug and install the transmission drain plug 11 Clean the sump drain plug and install the sump drain plug Illustration 294 QUO 1208 12 Fill the transmission with oil through filler tube 2 Refer to the Operation and Maintenance Manual Capacities Refill and the Operation and Maintenance Manual Lubricant Viscosities g00877251 Illustration 295 13 Remove the transmission breather 14 Wash the transmission breather in a clean nonflammable solvent 15 Install the transmission breather 16 Start the engine Run the engine at low idle Inspect the transmission for leaks 17 Slowly operate the transmission direction and speed control in order to circulate the oil 18 Maintain the oil level between the FULL and AD
18. OFF position Turn all switches to the OFF position 2 Turn the battery disconnect switch to the OFF position Remove the key 3 At the battery disconnect switch disconnect the negative battery cable that is connected to the frame Note Do not allow the disconnected battery cable to contact the disconnect switch 4 Check the battery terminals for corrosion If corrosion is present clean the battery terminals with a wire brush 5 Coat the battery terminals with petroleum jelly if necessary 6 Connect the negative battery cable at the battery disconnect switch 7 Install the key for the battery disconnect switch Turn the key to the ON position i00993589 Battery Recycle SMCS Code 1401 561 Always recycle a battery Never discard a battery Always return used batteries to one of the following locations e A battery supplier e An authorized battery collection facility e Recycling facility 101851175 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1402 040 1402 510 1 Turn the engine start switch to the OFF position Turn all switches to the OFF position 2 Turn the battery disconnect switch to the OFF position Remove the key 3 At the battery disconnect switch disconnect the negative battery cable that is connected to the frame Note Do not allow the disconnected battery cable to contact the disconnect switch 4 Disconnect the negative battery cable from
19. To Take A Good Oil Sample for more information about obtaining a sample of the transmission oil 101394768 Turbocharger Inspect SMCS Code 1052 040 If the turbocharger fails during engine operation severe damage to the turbocharger compressor wheel and to the entire engine can result Turbocharger bearing failures can cause large quantities of oil to enter the intake system and the exhaust system Loss of engine oil can result in serious engine damage Do not continue to operate the engine when a turbocharger bearing failure is accompanied by a significant loss of engine performance Engine smoke and speeding up of the engine with no load are characteristics of a loss of engine performance Reference For more information about inspecting the turbocharger refer to the appropriate Service Manual for your machine s engine 101774893 Wheel Coolant Level Check SMCS Code 4207 535 FLV With a lack of wheel coolant personal injury or death can result The brakes can generate enough heat to burn the tire bead A burning bead pro duces gases inside the tire that can explode en dangering personnel within 500 meters 1500 feet Illustration 306 g00907 284 Driven wheels Check fill plug 1 for the wheel coolant is located on the outer edge of the wheel The check fill plug is easily confused with drain plug 2 for the final drive Drain plug 2 has a symbol that is next to the plug For the correct
20. air cleaner housing Do not remove the two nuts that hold the air cleaner housing to the inlet manifold Remove the secondary element 3 Cover the air inlet opening Clean the inside of the air cleaner housing 4 Uncover the air inlet opening Install a new secondary element Tighten the nuts to a torque of 27 7 Nm 20 5 Ib ft 5 Install the primary element and the air cleaner housing cover Use your fingers to tighten the cover bolts Do not use a tool to tighten the bolts 101696854 Engine Air Filter Service Indicator Inspect SMCS Code 7452 040 NOTICE Service the air cleaner only with the engine stopped Engine damage could result g00102325 Illustration 226 1 Start the engine 2 Run the engine at high idle 3 If the yellow piston in the filter service indicator enters the red zone service the air cleaner 4 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 Note Refer to Operation and Maintenance Manual Engine Air Filter Service Indicator Inspect Replace in order to check an engine air filter service indicator that is faulty i01697515 Engine Air Filter Service Indicator Inspect Replace SMCS Code 7452 040 7452 510 1 Open the access door Illustration 227 g00873872 2 Stop the engine
21. as possible 6 Remove lower bolts for the wear plate 7 Replace shims or replace the wear plate Repeat the procedure for the other side of the bowl 114 Maintenance Section Ejector Carrier Rollers Check Adjust 101702702 Ejector Carrier Rollers Check Adjust SMCS Code 6229 025 6229 535 S N 6PR1 Up S N 7KR1 Up Park the machine on level ground Lower the bowl and close the apron Check the adjustment for the ejector carrier rollers The ejector carrier rollers are correctly adjusted if the ejector does not contact the bottom of the bowl The ejector carrier rollers are located at the bottom rear of the ejector Illustration 215 g00102197 1 Loosen roller shaft clamping bolt 1 2 Move eccentric roller shaft 2 to a position that allows the ejector to pass over the bottom of the bowl The ejector carrier rollers must be adjusted so that the clearance between the bottom of the ejector and the bottom of the bowl is between 1 0 to 13 0 mm 40 to 51 inch 3 Tighten roller shaft clamping bolt 1 4 Repeat Step 1 through Step 3 in order to adjust the other ejector carrier rollers 5 Start the engine Move the ejector forward and backward Stop the engine 6 Check for drag between the ejector and the bottom of the bowl Repeat the adjustment procedure if necessary i01702786 Ejector Carrier Rollers Inspect Pack Replace SMCS Code 6229 040 6229 086 6229 510 S N 6PR1 Up S
22. cylinder 4 Remove the used gasket Install the new gasket A new gasket is provided with each new ether starting aid cylinder 5 Install the new ether starting aid cylinder Tighten the ether starting aid cylinder hand tight Tighten the cylinder retaining clamp securely 6 Close the access cover i00060217 Fan Drive Bearing and Belt Tightener Lubricate SMCS Code 1358 086 1359 086 BD Note Wipe all the grease fittings before lubricating 1 Open the engine access cover on the right side of the engine g00102467 Illustration 250 2 Apply lubricant through fitting 1 for the fan drive bearing Apply lubricant through fitting 2 for the belt tightener 3 Close the engine access cover 101699358 Fuel System Prime SMCS Code 1250 548 S N 5YR1 Up S N 6TR1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 131 Maintenance Section Fuel System Prime 1 Open the access door on the right side o
23. for leaks Check the male fitting for leaks Check the filter for leaks Shut off the engine 12 Check the oil level on the dipstick 1 Maintain the oil between the marks on the SAFE OPERATING RANGE side of the dipstick If necessary add oil i00060058 Engine Oil Level Check SMCS Code 1000 535 FLV S N 5YR1 Up S N 6TR1 Up Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Do not under fill or overfill engine crankcase with oil Either condition can cause engine damage 1 Open the access cover that is on the right side of the machine g00102335 Illustration 236 2 Check the SAFE OPERATING RANGE side of dipstick 1 while the engine is running Maintain the oil level between the ADD mark and the FULL mark Check the SAFE STARTING RANGE side of dipstick 1 while the engine is stopped Maintain the oil level between the LOW mark and the FULL mark Note When you operate the machine on severe slopes the oil level in the engine crankcase must be at the FULL mark on the SAFE STARTING RANGE side of the dipstick 3 Remove oil filler cap 2 If necessary add oil 4 Clean the oil filler cap and install the oil filler cap 5 Close the access cover 125 Maintenance Section Engine Oil Level Check 101697977 Engine Oil Level Check SMCS Code 1000 5
24. for the second engine crankcase breather 11 Close the access cover Illustration 231 g00873938 2 Loosen the breather outlet hose clamps Remove the hose from the breather cover 3 Loosen the breather inlet hose clamp Remove the engine crankcase breather 4 Check the condition of the breather seal Replace the seal if the seal is damaged 5 Wash the breather in a clean nonflammable solvent 6 Shake the breather until the breather is dry You may also use pressure air to dry the breather 7 Check the condition of the hose Replace the hose if the hose is damaged 8 Install the breather 9 Install the hose and the breather outlet hose clamps 10 Repeat Step 2 to Step 9 for the second engine crankcase breather 11 Close the access cover 122 Maintenance Section Engine Oil High Speed and Oil Filter Change 101697778 Engine Oil High Speed and Oil Filter Change SMCS Code 1318 510 HZ S N 5YR1 Up S N 6TR1 Up Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and
25. inspection will not be used the primary air filter element can be stored for future use Illustration 224 g00281694 Do not use paint a waterproof cover or plastic as a protective covering for storage An airflow restriction may result To protect against dirt and damage wrap the primary air filter elements in Volatile Corrosion Inhibited VCI paper Place the primary air filter element into a box for storage For identification mark the outside of the box and mark the primary air filter element Include the following information e Date of cleaning e Number of cleanings Store the box in a dry location i00060042 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE NOTICE Always replace the secondary element Do not at tempt to reuse it by cleaning Engine damage could result Note Replace the engine air filter secondary element when you service the engine air filter primary element for the third time If a clean primary element has been installed and the engine air filter service indicator still enters the red zone replace the secondary element Also if the exhaust smoke remains black and a clean primary element has been installed replace the secondary element 1 Remove the air cleaner cover and the primary element Illustration 225 g00039214 119 Maintenance Section Engine Air Filter Service Indicator Inspect 2 Remove the nuts that hold the secondary element to the
26. of one ejector support roller to the outside of the other ejector support roller should be 0 75 to 1 50 mm 030 to 060 inch shorter than the narrowest dimension between the roller guide plates Consult your Caterpillar Dealer for further information 101702837 Ejector Support Rollers Inspect Pack Replace SMCS Code 6230 040 6230 086 6230 510 S N 6PR1 Up S N 7KR1 Up The ejector support rollers are located on the rear of the support assembly Remove any debris from the support rollers g00104419 Illustration 220 1 Inspect the support rollers 1 for damage Replace the support rollers if it is necessary 2 Grease the support roller at zerk 2 i01696727 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY NOTICE Service the air cleaner only with the engine stopped Engine damage could result Service the air cleaner filter element when the yellow piston on the engine air filter service indicator enters the red zone or the indicator reads 63 5 cm 25 inch of water Refer to Operation and Maintenance Manual Engine Air Filter Service Indicator Inspect Illustration 221 g00102316 1 Remove cover 1 for the air filter 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 fo
27. 128 Maintenance Section Engine Transfer Gear Scavenge Screen Clean Note Drain the crankcase while the oil is warm This allows waste particles that are suspended in the oil to drain As the oil cools the waste particles will settle to the bottom of the crankcase The particles will not be removed by draining the oil and the particles will recirculate in the engine lubrication system with the new oil 1 Remove the crankcase drain plug 1 2 Open the crankcase drain valve 2 Allow the oil to drain into a suitable container Close the drain valve Install the drain plug e gt a A o Remove the oil filter 3 with a strap type wrench See Operation and Maintenance Manual Oil Filter Inspect Discard the used oil filter properly 7 Clean the filter housing base Make sure that all of the old filter gasket is removed 8 Apply a thin coat of engine oil to the gasket of the new filter 9 Install the new filter by hand When the gasket contacts the filter base turn the filter by 270 degrees more This will tighten the filter sufficiently 10 Every new oil filter has marks which are for determining the rotation index These marks are spaced at 90 degree increments Use the rotation index marks as a guide for tightening the oil filter g00874406 Illustration 245 11 Clean the outside of the oil filler cap 4 Remove oil filler cap Fill the crankcase with new oil See Operation and
28. 35 FLV S N 6PR1 Up S N 7KR1 Up Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Do not under fill or overfill engine crankcase with oil Either condition can cause engine damage g00874164 Illustration 237 1 Check the SAFE OPERATING RANGE side of dipstick 1 while the engine is running Maintain the oil level between the ADD mark and the FULL mark Check the SAFE STARTING RANGE side of dipstick 1 while the engine is stopped Maintain the oil level between the LOW mark and the FULL mark Note When you operate the machine on severe slopes the oil level in the engine crankcase must be at the FULL mark on the SAFE STARTING RANGE side of the dipstick 2 Remove oil filler cap 2 If necessary add oil 3 Clean the oil filler cap and install the oil filler cap Engine Oil Sample Obtain SMCS Code 1000 008 7542 008 Illustration 238 g00874334 The sampling valve for the engine oil for the tractor is located on the filter base The engine oil filter is located on the right side of the engine in the engine compartment g00874330 Illustration 239 The sampling valve for the engine oil for the scraper is located on the filter base The engine oil filter for the scraper is located on the left side of the scraper engine Refer to Special Publication SEBU6250
29. 5YR1 Up S N 6TR1 Up NOTICE Replace fuses with the same type and size only Oth erwise electrical damage can result If it is necessary to replace fuses frequently an electri cal problem may exist Contact your Caterpillar dealer Fuses The fuses protect the electrical system from damage that is caused by overloaded circuits If the element inside the fuse separates replace the fuse Check the circuit if the element is separated in the new fuse Repair the circuit if necessary 136 Maintenance Section Hitch Inspect a Illustration 258 g00877436 The fuse panel is located inside the cab on the right front side Illustration 259 00O O 00 O g00877121 Apron Solenoid and Differential Lock 1 10 AMP Fuel Pump 2 10 AMP Rear Window Wiper and Washer 3 10 AMP Auxiliary Circuit 4 10 AMP Rear Flood Lights and Gauges 5 10 AMP Front Window Wiper and Washer 6 10 AMP EMS 7 10 AMP Transmission 8 10 AMP Air Dryer 9 10 AMP Backup Alarm 10 10 AMP Air Horn 11 10 AMP Bail and Cushion Hitch 12 10 AMP oO i00061542 Hitch Inspect SMCS Code 4305 040 7107 040 7113 040 g00102797 Illustration 260 137 Maintenance Section Hitch Lubricate Inspect the upper vertical hitch pin for wear or There are six shafts in the steering link Inspect the damage Replace the uppe
30. 68 g00101615 Apply lubricant through the two fittings on the inside of each tractor wheel Illustration 170 g00874965 g00101617 Illustration 169 Apply lubricant through one fitting on each scraper wheel g00101626 eats Illustration 171 There is a total of six fittings 1 Remove the wheel brake dust cover 2 Check the brake shoes for wear or for damage Measure the thickness of the brake linings If the thickness of the brake linings is less than 7 2 mm 28 inch replace the brake linings 3 Check the brake drum for wear or for damage Repair the brake drum or replace the brake drum if necessary 4 Install the wheel brake dust cover 99 Maintenance Section Brakes Indicators and Gauges Test 101349518 Brakes Indicators and Gauges Test SMCS Code 4251 081 4267 081 7000 7450 081 7490 081 Before you operate the machine perform the following checks and make any necessary repairs e Look for broken lenses on the gauges broken indicator lights broken switches and other broken components in the cab e Start the engine e Look for inoperative gauges e Turn on all machine lights Check for proper operation e Sound the forward horn e Move the machine forward and test the service brakes If the service brakes malfunction consult your Caterpillar Dealer for repairs e Engage the parking brake Move the machine forward in order to test the parking brake If th
31. 6TR1 Up NOTICE Do not attempt to straighten the ROPS structure Do not repair the ROPS by welding reinforcement plates to the structure If there are any cracks in the welds in the castings or in any metal section of the ROPS consult your Cater pillar dealer for repairs 1 Inspect the ROPS for loose bolts Inspect the ROPS for damaged bolts Replace the damaged bolts and the missing bolts with original equipment parts only Torque the bolts to 1050 150 N m 775 110 lb ft Note Apply oil to all ROPS bolt threads before you install the bolt Failure to apply oil can result in improper bolt torque 2 Operate the machine on a rough surface Replace the ROPS mounting supports if the ROPS makes a noise or if the ROPS rattles If there are any cracks in the welds in the castings or in any metal section of the ROPS consult your Caterpillar dealer for repairs i00061976 Seat Accumulator Check SMCS Code 7336 535 S N 5YR1 Up S N 6TR1 Up Illustration 277 g00103137 The seat accumulator is located under the operator s seat Check the nitrogen precharge pressure Consult your Caterpillar Dealer for the correct test procedure and consult your Caterpillar Dealer for the recommended pressure 144 Maintenance Section Seat Belt Inspect 101822494 Seat Belt Inspect SMCS Code 7327 040 S N 5YR1 Up S N 6TR1 Up
32. 97 Scraper 2 The differential and final drive breather is located on the transmission for the scraper 3 Remove the differential and final drive breather 4 Wash the breather in clean nonflammable solvent 5 Allow the breather to dry 6 Install the breather i01700953 Differential and Final Drive Oil Change SMCS Code 3258 044 4050 044 Wipe the openings around the covers and the surfaces before you fill the differential and final drives g00879363 Illustration 198 g00102114 Illustration 199 1 Remove the differential drain plug for the tractor and remove the differential drain plug for the scraper Drain the oil into a suitable container Note Always discard drained fluids according to local regulations Illustration 200 g00102117 2 Position each tractor wheel so that the drain plug on each wheel is at the lowest point Remove the drain plugs and allow the oil to drain into a suitable container 3 Clean the drain plugs and install the drain plugs 111 Maintenance Section Differential and Final Drive Oil Level Check Illustration 201 g00102116 Tractor g00875980 Illustration 202 Scraper 4 Remove the filler cap 5 Fill the differentials and the final drives See Operation and Maintenance Manual Capacities Refill Illustration 203 g00102117 6 Position each tractor wheel so that the filler plug on each wheel is in the corr
33. D OIL marks on the dipstick 1 Add oil through filler tube 2 if necessary 19 Stop the engine 151 Maintenance Section Transmission Oil Filter and Magnetic Screen Replace Clean 101704763 Transmission Oil Filter and Magnetic Screen Replace Clean SMCS Code 3030 070 MGS 3067 510 S N 5YR1 Up S N 6TR1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates The transmission oil filter is located on the top left side of the transmission case The magnetic screen is at the rear of the transmission case g00103184 Illustration 296 1 Remove the transmission filter housing drain plug Allow the oil to drain into a suitable container Note Discard the drained fluids according to local regulations Illustration 297 g00103185 2 Remove the bolts from the filter housing and remove the cover from the filter housing 3 Remove the used filter element and discard the used filter element 4 Clean the filt
34. FF position e The ejector must be moved forward e Apply slight downward pressure on the bowl Illustration 272 g00875179 If oil is needed add oil to the hydraulic tank The hydraulic oil filler cap 2 is located on top of the hydraulic tank 1 You should clean the cap before you remove the cap This cap is a locking cap You need to remove the padlock if a padlock is on the cap Raise the lever 3 in order to engage the lug Turn the cap counterclockwise in order to remove the cap Remove the cap slowly in order to relieve the air pressure 2 Add hydraulic oil until the oil level is at the full mark 3 Clean the cap Inspect the cap for damage to the seal Replace the seal if the seal is damaged 4 Install the oil filler cap 141 Maintenance Section Hydraulic System Oil Sample Obtain 101922442 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 7542 008 S N 5YR1 Up S N 6TR1 Up me mi Illustration 273 g00877183 The sampling valve for the hydraulic oil is located on top of the return tube and near the hydraulic tank Refer to Special Publication SEBU6250 S O S Oil Analysis for information that pertains to obtaining a sample of the hydraulic oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the hydraulic oil i00078390 Hydraulic Tank Breaker Relief Valve Clean SMCS Code 5118
35. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR Operation and Maintenance manual 657E Wheel Tractor Scraper 5YR1 Up Ma ne PR1 rape r ne AEN r h k Li ccc of iro aa G May 2003 90 Maintenance Section Maintenance Interval Schedule 101922460 Maintenance Interval Schedule SMCS Code 1000 7000 7500 7519 Note All safety information warnings and instructions must be read and understood before you perform any operation or any maintenance procedure Before each consecutive interval is performed all of the maintenance requirements from the previous interval must also be performed When Required Battery Recycle oo eeeeeeeteesneeeeeeeeneeeetennaeeers 94 Battery or Battery Cable Inspect Replace 94 Circuit Breakers Reset seneese 101 Cutting Edges and End Bits Inspect Replace 108 Draft Arm Flange Bolts Check sses 113 Draft Arm Wear Plates Check Adjust 113 Ejector Carrier Rollers Check Adjust 114 Ejector Guide Rollers Check Adjust 114 Ejector Support Rollers Check Adjust 115 Engine Air Filter Primary Element Clean Replace cccccceceseeeeeseeeseneeeseneeeseeees 116 Engine Air Filter Secondary Element Replace 118 Engine Air Filter Service Indicator nspect Replace ee eeececeeeeeeeeeee
36. N 7KR1 Up The ejector carrier rollers are located on the bottom rear of the ejector Remove any debris from the carrier rollers g00104412 Illustration 216 1 Inspect the carrier rollers for damage Replace the carrier rollers if it is necessary 2 Pack the carrier rollers See your Caterpillar dealer for further information on this procedure i01702798 Ejector Guide Rollers Check Adjust SMCS Code 6230 025 6230 535 S N 6PR1 Up S N 7KR1 Up Park the machine on level ground Lower the bowl and close the apron Check the adjustment for the ejector guide rollers The ejector guide rollers are correctly adjusted if the ejector does not contact the sides of the bowl The ejector carrier rollers are located on the rear sides of the ejector 115 Maintenance Section Ejector Guide Rollers Inspect Pack Replace Illustration 217 g00102248 1 Loosen roller shaft clamping bolt 1 2 Move eccentric roller shaft 2 to a position that allows the ejector to pass between the sides of the bowl The proper clearance between the ejector guide roller and the bowl is 3 0 to 20 0 mm 12 to 79 inch 3 Tighten roller shaft clamping bolt 1 4 Loosen roller shaft clamping bolt 3 5 Move eccentric roller shaft 4 to a position that allows the ejector to pass between the sides of the bowl 6 Tighten roller shaft clamping bolt 3 7 Repeat Step 1 through Step 6 in order to adjust the other e
37. NEUTRAL position Wipe all of the cover and wipe all of the surfaces around the opening before adding transmission oil C 2 Illustration 303 g00877359 1 Maintain the oil between the FULL and the ADD OIL marks on dipstick 1 2 Remove oil filler cap 2 and add oil if necessary 3 Clean the filler cap and install the filler cap 101922472 Transmission Oil Sample Obtain SMCS Code 3030 008 7542 008 S N 5YR1 Up S N 6TR1 Up g00877300 Illustration 304 The sampling valve for the tractor transmission is located at the rear of the transmission Refer to Special Publication SEBU6250 S O S Oil Analysis for information that pertains to obtaining a sample of the transmission oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the transmission oil 155 Maintenance Section Transmission Oil Sample Obtain 101922467 Transmission Oil Sample Obtain SMCS Code 3030 008 7542 008 S N 6PR1 Up S N 7KR1 Up g00877312 Illustration 305 The sampling valve for the scraper transmission is located on the top of the transmission filter The transmission filter is located on the left side of the scraper Refer to Special Publication SEBU6250 S O S Oil Analysis for information that pertains to obtaining a sample of the transmission oil Refer to Special Publication PEHP6001 How
38. See the Operation and Maintenance Manual Fuel System Prime for further instructions Note The primary fuel filter should also be changed at this time See the Operation and Maintenance Manual Fuel System Primary Filter Replace for further instructions Note The fuel system water separator also needs to be changed at this time See Operation and Maintenance Manual Fuel System Water Separator Element Replace 12 Start the engine and check for leaks 134 Maintenance Section Fuel System Water Separator Drain 101699594 Fuel System Water Separator Drain SMCS Code 1263 543 S N 5YR1 Up S N 6TR1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates g00874987 Illustration 255 The fuel system water separator is located on the right side of the engine below the primary fuel filter 1 Open drain 2 on water separator bowl 1 2 Drain the water from water separator bowl 1 Close the d
39. Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Your machine may be equipped with a high speed arrangement for changing the engine oil The high speed arrangement allows the oil to be quickly withdrawn The high speed arrangement allows the oil to be quickly replaced The high speed arrangement has a hose which is attached to the oil pan at the drain hole The other end of the hose has a quick coupler The quick coupler is located in the engine compartment on the right side of the tractor 1 Drain the crankcase while the oil is warm This allows waste particles that are suspended in the oil to drain As the oil cools the waste particles will settle to the bottom of the crankcase The particles will not be removed by draining the oil and the particles will recirculate in the engine lubrication system with the new oil Park the machine on a level surface Shut off the engine Apply the parking brake Illustration 232 2 g00874040 Clean the area around the dust cover 1 for the male quick coupler that is on the hose Remove the dust cover Clean the male fitting Remove the dust cover from female fitting of the suction hose Clean the female fitting Attach the suction hose to the male fitting Remove the oil from the engine Illustration 233 4 g00874065 Remove the filte
40. Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates g00875305 Illustration 282 The suction screen for the transmission is located at the rear of the transmission 1 Park the machine on level ground Lower the bowl Apply the parking brake Shut off the engine 2 Clean the area around the housing for the screen 3 Remove the drain plug 1 Allow the oil to drain into a suitable container 4 Remove the bolts 2 for the cover of the screen 5 Remove the cover 3 6 Remove the screen Clean the screen in nonflammable solvent Inspect the screen for damage Replace the screen if the screen is damaged 7 Install the screen Inspect the seal for the cover Replace the seal if the seal is damaged 8 Clean the cover Install the cover 9 Clean the plug Install the plug 10 Start the engine 11 Check the area around the screen housing for leaks 12 Check the transmission oil level Add oil if oil is needed
41. ator housing on the engine cylinder head 5 Install the elbow and the hose Tighten the hose clamp 101693168 Crankshaft Vibration Damper Inspect SMCS Code 1205 040 Damage to the vibration damper or failure of the vibration damper will increase torsional vibrations These vibrations will result in damage to the crankshaft and to the other engine components A deteriorating vibration damper will cause excessive gear train noise at variable points in the speed range 108 Maintenance Section Cutting Edges and End Bits Inspect Replace Caterpillar recommends replacing the vibration damper for any of the following reasons e The engine has had a failure because of a broken crankshaft e The S O S analysis detected a worn crankshaft front bearing e The S O S analysis detected a large amount of gear train wear that is not caused by a lack of oil The vibration damper can be used again if none of the above conditions are found or if the vibration damper is not damaged In the vibration damper a wobble can occur on the outer ring Some of the wobble of the outer ring is normal If a wobble is present replacement of the vibration damper may not be necessary To confirm an acceptable wobble see the Service Manual for the procedure to check the vibration damper Marks of the vibration damper are on the hub and on the outer ring These marks will indicate the condition of the vibration damper If the marks are
42. ay be found in the filter element This could be caused by friction and by normal wear Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings to the crankshaft and to other parts This can result in larger particles in unfiltered oil The particles could enter the lubricating system and the particles could cause damage 101699925 Push Plate Lubricate SMCS Code 6077 086 S N 5YR1 Up g00875237 Illustration 276 Apply 5P 0960 Molybdenum Grease to the face of the push plate with a putty knife This reduces the wear on the push plate Wear to the push block is reduced 101715240 Radiator Core Clean SMCS Code 1353 070 KO You can use compressed air high pressure water or steam to remove dust and other debris from the radiator core However the use of compressed air is preferred Note At the same interval clean the air conditioner condenser See Special Publication SEBD0518 Know Your Cooling System for the complete procedure for cleaning the radiator core 101823412 Refrigerant Dryer Replace SMCS Code 7322 710 A WARNING Personal injury can result from contact with refrig erant Contact with refrigerant can cause frost bite Keep face and hands away to help prevent injury Protective goggles must alw
43. ays be worn when re frigerant lines are opened even if the gauges in dicate the system is empty of refrigerant Always use precaution when a fitting is removed Slowly loosen the fitting If the system is still under pressure release it slowly in a well ventilated area Personal injury or death can result from inhaling refrigerant through a lit cigarette Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Do not smoke when servicing air conditioners or wherever refrigerant gas may be present Use a certified recovery and recycling cart to prop erly remove the refrigerant from the air condition ing system NOTICE If the refrigerant system has been open to the outside air without being plugged for more than 30 minutes the receiver dryer must be replaced Moisture will en ter an open refrigerant system and cause corrosion which will lead to component failure Refer to Service Manual SENR5664 Air Conditioning and Heating R 134a For All Caterpillar Machines for the proper procedure to change the receiver dryer assembly and for the procedure to reclaim the refrigerant gas 143 Maintenance Section Rollover Protective Structure ROPS Inspect 101696168 Rollover Protective Structure ROPS Inspect SMCS Code 7323 040 7325 040 S N 5YR1 Up S N
44. cknut 2 in the same manner as the alternator Refer to Specifications Alternator Belt Tightner for your machine 5 Tighten the compressor mounting bolt 1 6 If poor cooling is experienced turn off the air conditioner Stop the engine Consult your Caterpillar Dealer for air conditioner system service g00101037 i00058707 Bowl Lift Cylinder Bearings Illustration 161 1 Inspect the condition of the compressor drive belt If the compressor drive belt is worn or the Lubricate compressor drive belt is cracking replace the compressor drive belt Check the tension on the SMCS Code 5303 086 BD belt Refer to Specifications Belt Tension Chart for your engine If the belt deflection is not within Wipe the fittings before you apply lubricant to the the correct dimensions continue to Step 2 If the fittings belt deflection is correct go to Step 6 E 4 E g00101090 Illustration 162 999101038 H i Apply grease to one fitting for each of the bearings 2 Loosen the compressor mounting bolt 1 on the bowl lift cylinder Each side of the bowl has one fitting There are a total of two fittings Illustration 163 g00101041 3 Loosen the compressor locknut 2 97 Maintenance Section Brake Air System Pressure Test 101699405 Brake Air System Pressure Test SMCS Code 4250 081 PX Illustration 165 g0087488 1 1 Start the engine and look at the air pressure
45. ct Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates g00874798 Illustration 252 The fuel priming pump for the scraper is mounted on the left rear of the machine The pump is used when the following operations occur e Changing the fuel filters e Priming the fuel system e Changing the fuel lines e Purging air from the fuel system Note Do not attempt to start the engine until the fuel system is purged of air 1 Open the purge screw 2 on the secondary filter base 132 Maintenance Section Fuel System Secondary Filter Replace 2 Turn the knob 1 of the priming pump plunger counterclockwise in order to unlock the plunger 3 Pull up and push down on the knob in order to pump fuel Note The pump will fill the filters Note If the pump will not pump fuel the pump may be faulty or an air leak may occur on the suction side of the fuel system 4 Continue to prime the fuel system until the flow of fuel is free of air bubble s 5 Close the purge screw If you have only changed the fuel filters go to Step 8 If you have air in the fuel system for some other reason
46. d at the cab rear window The window wipers have replaceable wiper blades Replace the wiper blades when the following conditions occur e The wiper blades streak the windows of the cab e The wiper blades are damaged e The wiper blades are worn Note Damaged wiper blades may cause permanent damage to the glass of the cab windows 157 Maintenance Section Windows Clean 101698037 Windows Clean SMCS Code 7310 070 S N 5YR1 Up S N 6TR1 Up iG Illustration 309 g00874210 Use commercially available window cleaning solutions in order to clean the windows Lift the latch in order to slide the windows
47. d control to the NEUTRAL position Lower the bowl to the ground and stop the engine 101 Maintenance Section Cab Air Filter Clean Replace Note If the friction material for the brakes needs to be replaced the new friction material may require burnishing for maximum performance Consult your Caterpillar Dealer or see Special Instruction SEHS9580 for the procedure for burnishing 101699720 Cab Air Filter Clean Replace SMCS Code 7342 070 7342 510 Cleaning the Filters Outside Filters Note Clean the air filters more often during dusty conditions Illustration 176 g00101782 1 Open the access cover The access cover is on the front of the cab g00101783 Illustration 177 2 Remove the filter elements Clean the filter elements with pressure air or wash the filter elements in warm water Use a nonsudsing household detergent 3 After you clean the filter element inspect the filter element Do not use a filter element with damaged pleats a damaged gasket or damaged seals 4 Rinse the filter elements in clean water and air dry the filter elements thoroughly 5 Install the filter elements Close the access cover Inside Filter g00875098 Illustration 178 1 Remove the access cover The access cover is on the inside of the cab 2 Remove the filter element Clean the filter element with pressure air or wash the filter element in warm water Use a nonsudsing household deter
48. e parking brake malfunctions consult your Caterpillar Dealer for repairs e Stop the engine i01699620 Braking System Test SMCS Code 4251 081 4267 081 Service Brake Holding Ability Test A WARNING Personal injury can result if the machine moves while testing If the machine begins to move during test reduce the engine speed immediately and engage the parking brake NOTICE If the machine moved while testing the brakes contact your Caterpillar Dealer Have the dealer inspect and if necessary repair the service brakes before returning the machine to operation Make sure that the area around the machine is clear of personnel and of obstacles Test the brakes on a dry level surface Fasten the seat belt before you test the brakes The service brake holding ability test determines whether the service brake is functional This test is not intended to measure the maximum brake holding effort The brake holding effort that is required to hold a machine at a specific engine rom will be different for various machines This is due to variances in the engine setting in the power train efficiency and in the brake holding ability When the machine begins to move the engine rom should be compared to a prior test Use the comparison as an indication of system deterioration Illustration 172 g00874881 1 Start the engine and look at the air pressure gauge Allow the brake system air pressure to reach 850
49. e reused if the water temperature regulators are within test specifica tions are not damaged and do not have excessive buildup of deposits NOTICE Since Caterpillar engines incorporate a shunt design cooling system it is mandatory to always operate the engine with a water temperature regulator Depending on load failure to operate with a water tem perature regulator could result in either an overheating or an overcooling condition NOTICE If the water temperature regulator is installed incor rectly it will cause the engine to overheat Replace the water temperature regulator on a regular basis Regular replacement of the temperature regulator will reduce the chance of down time due to problems with the cooling system The water temperature regulator should be replaced after the cooling system has been cleaned Replace the water temperature regulator while the cooling system level is below the housing assembly 1 Loosen the hose clamp and remove the hose from the elbow Disconnect the hose assembly from the water temperature regulator housing 2 Remove the bolts from the elbow Remove the elbow and the water temperature regulator housing 3 Remove the gasket the water temperature regulator and the seal from the water temperature regulator housing 4 Install a new seal in the water temperature regulator housing Install a new water temperature regulator and a new gasket Install the water temperature regul
50. ean c eee 147 Transmission Breather Clean c ee 147 Transmission Oil Change 147 Transmission Oil Change 149 Wheel Coolant Level Check cccccceecseeeeees 155 Every 2000 Service Hours or 1 Year Brake Shoes and Drums Inspect Replace 98 Differential Thrust Pin Clearance Check 109 Differential and Final Drive Oil Change 110 Ejector Carrier Rollers Check Adjust 114 Ejector Carrier Rollers Inspect Pack Replace 114 Ejector Guide Rollers Check Adjust 5 114 Ejector Guide Rollers Inspect Pack Replace 115 Ejector Support Rollers Check Adjust 115 Ejector Support Rollers Inspect Pack Replace 116 Engine Valve Lash Check seeen 129 Engine Valve Rotators Inspect 129 Hitch INSPCCt accenna 136 Refrigerant Dryer Replace eeeeeeeeeeeees 142 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace cccccesceeeseeeeeteeeeeteeeeeees 144 Every 3000 Service Hours or 3 Years Cooling System Pressure Cap Clean Replace 106 Cooling System Relief Valve Clean 006 106 Cooling System Water Temperature Regulator REPISTO ee 107 Crankshaft Vibration Damper Inspect 107 Every 4000 Service Hours Hydraulic System Oil Change c cceeeee 137 Every 5000 Service Hours or 3 Years T
51. ect position Remove the filler plugs Fill the final drives 7 Clean the filler plug Install the filler plug 8 Clean the filler cap and install the filler cap Illustration 204 g00102118 Tractor A TA g00875979 Illustration 205 Scraper 9 Maintain the differential oil level between the marks on the dipstick Differential and Final Drive Oil Level Check SMCS Code 3258 535 FLV 4050 535 FLV Clean covers and surfaces around any openings before you add oil 112 Maintenance Section Differential and Final Drive Oil Sample Obtain Illustration 206 g00876011 The oil level dipstick for the differential and for the final drive is on the left rear side of the tractor The oil level dipstick for the differential and for the final drive is on the rear of the scraper Illustration 207 g00102125 Tractor Illustration 208 g00876012 Scraper 1 The proper oil level is between the FULL and ADD on the dipstick 1 2 Remove oil filler cap 2 and add oil if necessary 3 Clean the oil filler cap and install the oil filler cap 101859475 Differential and Final Drive Oil Sample Obtain SMCS Code 3258 008 4050 008 7542 008 Illustration 209 g00947846 1 Filler tube for the differential and final drive tractor Illustration 210 g00947847 2 Filler tube for the differential and final drive scraper A sample of the differential and the fi
52. ed control in order to circulate the oil Illustration 291 g00103214 19 Maintain the oil level between the FULL and ADD OIL marks on the dipstick 1 Add oil through filler tube 2 if necessary 20 Stop the engine i01704781 Transmission Oil Change SMCS Code 3030 044 S N 6PR1 Up S N 7KR1 Up Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Operate the engine until the transmission oil is warm Park the machine on a level surface Lower the bowl until the bowl exerts a slight downward pressure on the ground 150 Maintenance Section Transmission Oil Change Engage the parking brake Stop the engine 1 The transmission drain plug is located under the transmission Illustration 292 g00877463 2 Remove the transmission drain plug and drain the oil into a suitable container
53. eeeeeteteeeteaeeeeaes 119 Engine Air Filter Service Indicator Screen Check Replace cccececeeseeeeeseeeseneeeseeeeeeenees 120 Engine Transfer Gear Scavenge Screen CIS AM EE AREE EEA adel estes 128 Ether Starting Aid Cylinder Replace 129 Ether Starting Aid Cylinder Replace 130 Fuel System Prime seeen 130 Fuel System Prime eeens 131 Fuses Replace cccesscceeeeeseeeeesenseceeeeeseenes 135 Hydraulic Tank Breaker Relief Valve Clean 141 Oil Filter Inspect ee eee eeeeeeeeeeeeeteeteteeeteteees 141 Seat Accumulator Check sssr 143 Seat Oil Line Screen Clean eese 144 Window Washer Reservoir Fill laee 156 Window Wiper Inspect Replace 0 156 Windows Clean ececeeeeeeeeeeeeteeeeeeeaeeeeeaeeteneees 157 Every 10 Service Hours or Daily Air Tank Moisture and Sediment Drain 93 Backup Alarm Test ssseesiieserrrrssrrrrerrrrrrerrrnnese 93 Brakes Indicators and Gauges Test 05 99 Cooling System Coolant Level Check 105 Differential and Final Drive Oil Level Check 111 Engine Air Filter Primary Element Clean Replace cccccecccceeeeeceseeeteneeeseeeeeeeees 116 Engine Air Filter Service Indicator Inspect 119 Engine Air Precleaner Clean ccecce 120 Engine Oil Level Check sussen 124 Engine Oil Level Check ssec 125 Fuel System Water Separator Drain
54. engine and run the engine at low idle Illustration 247 g00102450 2 Watch the top surface of each valve rotator When the intake valve or the exhaust valve closes the engine valve rotator should turn slightly If an intake valve or an exhaust valve fails to rotate consult your Caterpillar Dealer i00060184 Ether Starting Aid Cylinder Replace SMCS Code 1456 510 CD S N 5YR1 Up S N 6TR1 Up 1 The ether starting aid cylinder is mounted on the right side of the engine compartment 2 Open the access cover g00102454 Illustration 248 130 Maintenance Section Ether Starting Aid Cylinder Replace 3 Loosen the cylinder retaining clamp Unscrew the empty ether starting aid cylinder and remove the empty ether starting aid cylinder 4 Remove the used gasket Install the new gasket A new gasket is provided with each new ether starting aid cylinder 5 Install the new ether starting aid cylinder Tighten the ether starting aid cylinder hand tight Tighten the cylinder retaining clamp securely 6 Close the access cover 101698753 Ether Starting Aid Cylinder Replace SMCS Code 1456 510 CD S N 6PR1 Up S N 7KR1 Up 1 The ether starting aid cylinder is mounted on the right side of the scraper 2 Open the access cover Illustration 249 g00874621 3 Loosen the cylinder retaining clamp Unscrew the empty ether starting aid cylinder and remove the empty ether starting aid
55. er housing and the transmission filter housing drain plug with a clean nonflammable solvent 5 Insert a new filter element into the filter housing 6 Inspect the filter housing seal Replace the filter housing seal if the filter housing seal is damaged 7 Install the cover on the filter housing 8 Install the transmission filter housing drain plug in the filter housing g00103186 Illustration 298 9 Remove the magnetic screen cover slowly Allow the oil to drain into a suitable container 10 Remove the magnetic screen 11 Separate the magnets and the tube assembly from the screen 152 Maintenance Section Transmission Oil Filter and Magnetic Screen Replace Clean 12 Wash the screen and the tube assembly in a clean nonflammable solvent 13 Allow the screen and the tube assembly to dry NOTICE Do not drop or rap magnets on hard objects or dam age can result Replace damaged magnets 14 Clean the magnets with a cloth or with a stiff bristle brush Allow the magnets to dry 15 Install the magnets and the tube assembly into the screen 16 Install the magnetic screen 17 Inspect the cover seal Replace the cover seal if the cover seal is damaged 18 Install the cover and tighten the bolts 19 Start the engine Apply the service brake 20 Slowly operate the transmission direction and speed control in order to circulate the transmission oil 21 Move the transmission direction and s
56. et that is part of the fuel cap Inspect the gasket for damage Replace the gasket if the old gasket is damaged 3 Disassemble the fuel tank cap Remove the filter elements Clean the filter elements in clean nonflammable solvent Apply a thin coat of oil to the filter elements Assemble the fuel tank cap Install the gasket 4 Remove the strainer Clean the strainer in clean nonflammable solvent Install the strainer 5 Install the fuel tank cap i01699660 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates g00875051 Illustration 257 The drain valve is under the fuel tank on the right side of the machine 1 Remove the plug from the drain valve 2 Open the drain valve Allow the water and the sediment to drain into a suitable container 3 Close the drain valve Install the drain valve plug i01703577 Fuses Replace SMCS Code 1417 510 S N
57. f oil is needed 101708528 Transmission Oil Level Check SMCS Code 3030 535 FLV S N 5YR1 Up S N 6TR1 Up The dipstick for the transmission oil level is located on the back left side of the tractor Note The machine must meet the following conditions before checking the transmission oil level e The machine must be level e The parking brake must be engaged e The transmission oil must be warm e The engine must be running at low idle e The transmission direction and speed control must be in the NEUTRAL position Wipe all of the cover and wipe all of the surfaces around the opening before adding transmission oil g00103257 Illustration 302 1 Maintain the oil between the FULL and the ADD OIL marks on dipstick 1 2 Remove oil filler cap 2 and add oil if necessary 3 Clean the filler cap and install the filler cap 154 Maintenance Section Transmission Oil Level Check 101704587 Transmission Oil Level Check SMCS Code 3030 535 FLV S N 6PR1 Up S N 7KR1 Up The dipstick for the transmission oil level is located on the backright side of the scraper Note The machine must meet the following conditions before checking the transmission oil level e The machine must be level e The parking brake must be engaged e The transmission oil must be warm e The engine must be running at low idle e The transmission direction and speed control must be in the
58. f the machine p a g00102470 Illustration 251 2 Turn the priming pump plunger counterclockwise and pull out the priming pump plunger 3 Operate the fuel priming pump in order to fill the new filter element Continue to operate the fuel priming pump until the pump resists operation This indicates that the filter element is full of fuel 4 Push the priming pump plunger downward and turn the priming pump plunger clockwise in order to lock the priming pump plunger 5 Start the engine Look for leaks around the filter element If the engine will not start or the engine misfires more priming is necessary 6 If the engine runs rough after start up shut off the engine Loosen the vent plug on the block for the fuel return The block for the fuel return is at the upper left rear of the engine Release the priming pump plunger and prime the fuel system until a continuous stream of fuel is flowing from the opening Catch the fuel in a suitable container Install the vent plug and lock the priming pump plunger Start the engine and run the engine at low idle until the engine does not run rough Note Discard any drained fluids according to local regulations 7 Close the access door 101699237 Fuel System Prime SMCS Code 1250 548 S N 6PR1 Up S N 7KR1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the produ
59. gauge Allow the brake system air pressure to reach 850 50 kPa 125 10 psi g00872910 Illustration 166 2 Apply the service brake control and hold down the service brake control 3 Stop the engine 4 The reading on the air pressure gauge should not drop more than 35 kPa 5 psi after the engine is stopped for 10 minutes Repair the brakes if necessary 100768566 Brake Air System Warning Horn Test SMCS Code 7402 081 7408 081 The warning horn for the air brake system should sound when the air pressure gauge shows a reading below 450 kPa 65 psi 1 The parking brake should be in the ENGAGED position 2 The lever for the transmission control should be in the NEUTRAL N position 3 Start the engine 4 Watch the air pressure gauge The air pressure must be above 450 kPa 65 psi 5 Purge air from the air tanks by doing the following procedure e Engage and disengage the service brake until the air pressure drops below 450 kPa 65 psi The warning horn should sound Make repairs if the horn is not sounding i01699565 Brake Camshaft Bearing Lubricate SMCS Code 4251 086 BD Wipe all of the fittings before you apply lubricant through the fittings Illustration 167 g00874965 98 Maintenance Section Brake Shoes and Drums Inspect Replace 101699587 Brake Shoes and Drums Inspect Replace SMCS Code 4252 040 4252 510 4253 040 4253 510 Illustration 1
60. gent 3 After you clean the filter element inspect the filter element Do not use a filter element with damaged pleats a damaged gasket or damaged seals 4 Rinse the filter element in clean water and air dry thoroughly 5 Install the filter element Install the access cover 101699848 Circuit Breakers Reset SMCS Code 1420 529 S N 5YR1 Up S N 6TR1 Up Circuit Breaker Reset Push in the button in order to reset the circuit breaker If the electrical system is working properly the button will remain depressed If the button does not remain depressed check the appropriate electrical circuit Repair the electrical circuit if necessary 102 Maintenance Section Cooling System Coolant Sample Obtain Illustration 179 g00875164 4 Alternator 1 80 AMP C Blower Motor 2 15 AMP Engine Control 3 15 AMP Key Switch 4 10 AMP Cooling System Coolant Sample Obtain SMCS Code 1395 554 S N 5YR1 Up S N 6TR1 Up aa g00102060 Illustration 180 The cooling system is not equipped with a sampling valve Obtaining a sample of the cooling system will require a vacuum pump or an equivalent Withdraw the fluid through the cooling system pressure cap For additional information about coolant analysis refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 101925448 Cooling System Coolant Sample Ob
61. he cap Replace the gasket if necessary 5 Install the pressure cap i01700532 Cooling System Relief Valve Clean SMCS Code 1370 070 Illustration 188 g00102094 Tractor g00878974 Illustration 189 Scraper The cooling system relief valve is located on the top of the hood at the front of the machine 1 Remove the cooling system pressure cap slowly in order to relieve the pressure 107 Maintenance Section Cooling System Water Temperature Regulator Replace Illustration 190 g00102095 2 Remove the mounting bolts 1 Remove the cover 5 gaskets 2 plate 3 and valve assembly 4 3 Inspect the valve assembly 4 plate 3 and gaskets 2 Replace any of these components if necessary 4 Inspect valve cover 5 and mounting bolts 1 5 Inspect the components for damage and for foreign matter Replace the valve assembly if the valve assembly is damaged 6 Install the valve assembly 4 Install the plate 3 gaskets 2 cover 5 and the mounting bolts 1 7 Maintain the coolant level within 13 mm 5 inch of the bottom of the filler pipe 8 Install the cooling system pressure cap 101700613 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 NOTICE Failure to replace the engine s water temperature reg ulator on a regularly scheduled basis could cause se vere engine damage NOTICE The water temperature regulators may b
62. housing 1 5 Remove the used filter element and discard the used filter element 153 Maintenance Section Transmission Oil Level Check 6 Clean the inside of the filter housing with a clean towel 7 Insert a new filter element into the filter housing 8 Inspect the filter housing seal Replace the seal if the seal is damaged 9 Install the cover on the filter housing 10 Install the transmission filter housing drain plug in the filter housing g00877371 Illustration 301 The magnetic screen is located on the left side of the transmission for the scraper 1 Remove the bolts 3 2 Remove the cover 4 3 Remove the screen 4 Separate the magnets from the screen Wash the screen and the magnets in a nonflammable solvent Note Do not rap the magnets on hard objects The magnets may be damaged Replace damaged magnets 5 Allow the cleaned parts to dry Use compressed air pressure in order to speed the drying of the parts 6 Clean the magnets with a towel or clean the magnets with a stiff bristle brush 7 Install the magnets into the screen 8 Install the magnetic screen into the housing 9 Install the cover and the bolts 10 Start the engine Apply the parking brake 11 Run the engine at low idle 12 Check the filter for leaks Check the magnetic screen for leaks 13 Shut off the engine 14 Check the oil level of the transmission Some oil may be needed Add oil i
63. identification of drain plug 2 refer to Operation and Maintenance Manual Differential and Final Drive Oil Change 1 Check fill plug 1 must be horizontal with the center line of the axle in order to check the coolant level 2 Clean the area around the plug hole 3 Remove the plug Antifreeze should be dripping from the hole 156 Maintenance Section Window Washer Reservoir Fill 4 Add antifreeze if antifreeze is needed A solution of 50 percent water and 50 percent Caterpillar antifreeze is preferable If Caterpillar antifreeze is not used commercially available ethylene glycol type antifreeze can be a substitute 5 Clean the plug Install the plug 6 Perform the same procedure to the other driven wheels i01698056 Window Washer Reservoir Fill SMCS Code 7306 544 S N 5YR1 Up S N 6TR1 Up NOTICE Use Caterpillar nonfreezing window washer solvent or a commercially available windshield washer fluid in order to prevent freezing of the windshield washer system Illustration 307 Open the access panel 1 Remove the cap of the reservoir 2 Fill the window washer reservoir through the filler opening 3 Replace the cap of the reservoir 4 Close the access panel 101364987 Window Wiper Inspect Replace SMCS Code 7305 040 7305 510 S N 5YR1 Up S N 6TR1 Up Illustration 308 900787891 One window wiper is located at the cab front window One window wiper is locate
64. illar Machine Fluids Rec ommendations NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates If the coolant in the machine is changed to Extended Life Coolant from another type of coolant see Special Publication SEBU6250 Extended Life Coolant ELC 1 Allow the engine to cool 2 Loosen the pressure cap slowly in order to release pressure Remove the pressure cap Illustration 182 g00102061 3 Radiator drain 1 is located under the right side of the tractor 4 Remove bolt 2 in order to remove the cover plate for the radiator drain Open the drain valve 5 Flush the cooling system with clean water until the draining water is transparent 6 Close the drain valve Install the cover plate and the bolt 7 Add the Extended Life Coolant Refer to the following topics e Operation and Maintenance Manual SEBU6250 Cooling System Specifications e Operation and Maintenance Manual Capacities Refill
65. ine in order to inspect the fan drive belts The fan drive belts run on a pulley that is spring loaded There is no adjustment for the pulley that is spring loaded Replace the belts if the belts are worn or if the belts are damaged Alternator Belt Note The alternator belt for the scraper is adjusted in the same manner as the tractor Illustration 160 g00101053 1 To adjust the alternator belt loosen the alternator mounting bolt 1 Loosen the adjusting locknut 2 2 Turn the adjusting nut 3 until the correct belt tension is reached Tighten the adjusting locknut 2 to the proper torque Refer to Specifications Alternator Belt Tightner for your machine 3 Tighten the alternator mounting bolt 1 4 If new belts are installed check the belt adjustment again after 30 minutes of engine operation at the rated speed Air Conditioner Belt A WARNING Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Do not smoke when servicing air condi tioners or wherever air conditioner refrigerant gas may be present 96 Maintenance Section Bowl Lift Cylinder Bearings Lubricate 4 Turn the adjusting nut 3 until the correct belt tension is reached Refer to Specifications Belt Tension Chart for your engine Tighten the compressor lo
66. jector guide rollers 8 Start the engine Move the ejector forward and move the ejector backward Stop the engine 9 Check for drag between the ejector guide rollers and the bowl Repeat the adjustment procedure if necessary 101702816 Ejector Guide Rollers Inspect Pack Replace SMCS Code 6230 040 6230 086 6230 510 S N 6PR1 Up S N 7KR1 Up The ejector guide rollers are located on the back side of the ejector and at the top of the ejector Remove any debris from the guide rollers Illustration 218 g00104414 1 Inspect the guide rollers for damage Replace the guide rollers if it is necessary 2 Pack the guide rollers See your Caterpillar Dealer for further information on this procedure 101702823 Ejector Support Rollers Check Adjust SMCS Code 6230 025 6230 535 S N 6PR1 Up S N 7KR1 Up Park the machine on level ground Lower the bowl and close the apron Check the adjustment for the ejector support rollers The ejector support rollers are correctly adjusted if the ejector support rollers do not bind against the frame of the ejector The support rollers are located on the rear of the support assembly g00102292 Illustration 219 116 Maintenance Section Ejector Support Rollers Inspect Pack Replace Install the necessary amount of shims in order to achieve the correct clearance between the ejector support rollers and the roller guide plates The distance from the outside
67. l time for the engine to cool before mea suring adjusting valve lash clearance NOTICE Only qualified service personnel should perform this maintenance Refer to the Service Manual or your Caterpillar dealer for the complete valve lash adjust ment procedure Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life The initial valve lash adjustment is recommended at the first scheduled oil change The valve lash adjustment should then be made at every 2000 hour interval The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train components This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life Ensure that the engine is stopped before measuring the valve lash To obtain an accurate measurement allow the valves to cool before this maintenance is performed Refer to the Service Manual for more information i00060158 Engine Valve Rotators Inspect SMCS Code 1109 040 A WARNING When inspecting the valve rotators protective glasses or face shield and protective clothing must be worn to prevent being burned by hot oil Spray Inspect the engine valve rotators after the valve clearances have been set 1 Start the
68. llar dealer for the replacement of the seat belt i01699996 Seat Oil Line Screen Clean SMCS Code 7324 070 Z3 S N 5YR1 Up S N 6TR1 Up Note The hydraulic suspension seat is an attachment for this machine 1 Lower the seat completely and stop the engine 145 Maintenance Section Steering Pump Outlet Screen Clean Illustration 280 g00103138 2 Disconnect the oil line at the rear of the operator seat 3 Remove the screen 4 Wash the screen in a clean nonflammable solvent Allow the screen to dry 5 Install the screen and connect the oil line i01700012 Steering Pump Outlet Screen Clean SMCS Code 4306 070 Z3 S N 5YR1 Up S N 6TR1 Up g00103067 Illustration 281 Note Clean the steering pump outlet screen when there is pump failure or pump change in the hydraulic system The steering pump outlet screen is located inside the left frame rail of the tractor 1 Remove the bolts 1 and the screen cover 2 2 Inspect the cover seal 3 Replace the cover seal 3 if the seal is damaged 3 Remove the steering pump outlet screen 4 Clean the screen 4 and the screen cover 2 in a nonflammable solvent 4 Install the screen 4 cover seal 3 cover 2 and bolts 1 146 Maintenance Section Suction Screen Transmission Scavenge Clean i01700024 Suction Screen Transmission Scavenge Clean SMCS Code 3030 070 Z3 S N 5YR1 Up S N 6TR1
69. llect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 263 g00102800 138 Maintenance Section Hydraulic System Oil Change Note If the hydraulic oil is not being monitored by the Caterpillar S O S Oil Analysis program change the hydraulic oil at every 2000 service hour interval The machine must meet the following conditions before you change the hydraulic tank oil e The machine must be level e The parking brake must be applied e The hydraulic oil must be warm e The transmission control must be in NEUTRAL e The bowl must be lowered Wipe all surfaces around openings before adding oil 1 Move the hydraulic controls in order to relieve the system pressure Illustration 265 g00102868 2 Remove the oil filler cap for the hydraulic system slowly in order to relieve pressure Also remove the oil filler strainer 3 Wash the filler screen and the filler cap in a clean nonflammable solvent g00102872 Illustration 266 4 Remove the drain plug 1 The drain plug is located in the bottom of the hydraulic tank 5 Open the tank drain valve 2 Allow the oil to drain into a suitable container Close the tank drain valve Note Discard the drained fluids according to local regulations 6 Change the hydraulic system filters See Operation and Maintenance Manual Hydraulic System Oil Filter Replace 7
70. maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates g00874976 Illustration 254 The secondary fuel filter for the scraper is mounted on the left rear of the machine 1 Park the machine on a level surface Lower the bowl Shut off the engine Move the fuel valve to the CLOSED position a A O ND Clean the secondary filter 2 Clean the filter base 1 which is located above the filter 6 Turn the filter to the left in order to loosen the filter Loosen the filter with a strap type wrench 7 Remove the filter Clean the bottom of the filter base Make sure that all of the old filter seal is removed 8 Apply clean diesel fuel to the seal of the new secondary filter 9 Install the new filter by hand When the seal contacts the base tighten the filter for an additional 3 4 turn Rotation index marks are positioned on the filters at 90 degree intervals Use these rotation index marks as a guide when you tighten the filter 10 Return the fuel valve to the OPEN position 11 Purge the air from the fuel system
71. mmendations NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates If the coolant in the machine is changed to Extended Life Coolant from another type of coolant see Special Publication SEBU6250 Extended Life Coolant ELC 1 Allow the engine to cool 2 Loosen the pressure cap slowly in order to release pressure Remove the pressure cap Illustration 183 g00878952 3 Radiator drain 1 is located under the right side of the tractor 4 Remove bolt 2 in order to remove the cover plate for the radiator drain Open the drain valve 5 Flush the cooling system with clean water until the draining water is transparent 6 Close the drain valve Install the cover plate and the bolt 7 Add the Extended Life Coolant Refer to Operation and Maintenance Manual Capacities Refill 8 Start the engine Operate the engine without the cooling system pressure cap until the water temperature regulator opens and the co
72. n in order to perform the test Apply the service brakes Move the transmission control lever to the REVERSE position The backup alarm should start to sound immediately The backup alarm will continue to sound until the transmission control lever is moved to the NEUTRAL position or to the FORWARD position To adjust the volume level turn the three position adjustment knob on the back of the backup alarm The three position adjustment knob is set to the HIGH setting when the machine is shipped from the factory The Three position adjustment knob should remain at the HIGH setting unless the job site requires a lower volume level 94 Maintenance Section Bail Bearings and Push Plate Spring Lubricate 101779494 Bail Bearings and Push Plate Spring Lubricate SMCS Code 6262 086 7115 086 BD S N 5YR1 Up S N 6TR1 Up DODDDODODOD goo909682 Illustration 158 One grease fitting 1 is located on each side of the bail Grease fitting 2 is located on the spring for the push plate The grease fittings for the bearings of the bail and the push plate spring are located at the front of the tractor 1 Clean the grease fittings 2 Remove the covers that are on the fittings 3 Lubricate the three fittings 4 Replace the covers that are on the fittings 101851167 Battery Clean Check SMCS Code 1401 070 1401 535 1402 070 1402 535 1 Turn the engine start switch to the
73. n operating without an air dryer Several weeks may be required in order to completely dry the system i00058662 Air Dryer Desiccant Replace SMCS Code 4285 510 DSS S N 5YR1 Up S N 6TR1 Up Air lines to and from the air dryer must be at atmo spheric pressure Release the air pressure from the air system completely before performing main tenance 93 Maintenance Section Air Tank Moisture and Sediment Drain Illustration 155 g00101049 Replace the air dryer desiccant cartridge or rebuild the air dryer desiccant cartridge if water cannot be absorbed Consult your Caterpillar Dealer for service or for replacement parts 101698110 Air Tank Moisture and Sediment Drain SMCS Code 4272 543 M amp S The two tractor air reservoir drain valves are on the right side of the tractor g00101050 Illustration 156 Open the tractor air reservoir drain valves Allow the moisture and the sediment to drain into a suitable container Close the tractor air reservoir drain valves The scraper air reservoir drain valve is on the right rear side of the scraper Illustration 157 g00101051 Open the scraper air reservoir drain valve Allow the moisture and the sediment to drain into a suitable container Close the scraper air reservoir drain valve 101349483 Backup Alarm Test SMCS Code 7406 081 The backup alarm is on the rear of the machine Turn the engine start switch to the ON positio
74. n the area around the breather 2 Remove the breather 3 Wash the breather in clean nonflammable solvent 4 Allow the breather to dry 5 Install the breather 101700216 Transmission Oil Change SMCS Code 3030 044 S N 5YR1 Up S N 6TR1 Up Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin 148 Maintenance Section Transmission Oil Change NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Operate the engine until the transmission oil is warm Park the machine on a level surface Lower the bowl until the bowl exerts a slight downward pressure on the ground Engage the parking brake Stop the engine 1 The transmission drain plug is located under the transmission g00103203 Illustration 286 2 Remove the transmission drain plug and drain the oil into a suitable container Note Discard the drained fluids according to local regulations
75. nal drive oil can be obtained by pulling a sample through the filler tube Filler tube 1 is located on the left rear side of the tractor Filler tube 2 is located on the right rear side of the scraper engine Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the differential and final drive oil 113 Maintenance Section Draft Arm Flange Bolts Check 101701191 Draft Arm Flange Bolts Check SMCS Code 6204 527 BC S N 6PR1 Up S N 7KR1 Up Illustration 211 g00102137 Torque the bolts for the draft arm Refer to Specifications Draft Frame for the proper torque Consult your Caterpillar dealer for the tightening procedure for the flange bolts 101703526 Draft Arm Wear Plates Check Adjust SMCS Code 6204 025 WK 6204 535 WK S N 6PR1 Up S N 7KR1 Up g00102145 Illustration 212 1 Check the clearance between shoe 1 and draft arm wear plate 2 Refer to Specifications Draft Frame for necessary clearance Add shims if necessary Illustration 213 2 Chock the wheels g00883349 Illustration 214 3 Use a suitable lifting device in order to lift the rear of the scraper Lift the rear of the scraper in order to place the bowl in the lowest possible position Support the rear of the scraper for safety 4 Remove the upper bolts for the wear plate 5 Remove cribbing and raise the bowl as far
76. ne air precleaner is positioned on top of the engine compartment Illustration 229 g00805907 1 Loosen clamp 1 at the bottom of engine air precleaner 2 2 Remove engine air precleaner 2 and inspect the opening for dirt and debris Clean the tubes if necessary 3 Clean engine air precleaner 2 with pressure air or wash the engine air precleaner 2 in clean warm water 4 Install engine air precleaner 2 Tighten clamp 1 121 Maintenance Section Engine Crankcase Breather Clean i00060057 Engine Crankcase Breather Clean SMCS Code 1317 070 S N 5YR1 Up S N 6TR1 Up 1 Open the access cover 101697582 Engine Crankcase Breather Clean SMCS Code 1317 070 S N 6PR1 Up S N 7KR1 Up 1 Open the access cover if equipped g00102333 Illustration 230 2 Loosen the breather outlet hose clamps Remove the hose from the breather cover 3 Loosen the breather inlet hose clamp Remove the engine crankcase breather 4 Check the condition of the breather seal Replace the seal if the seal is damaged 5 Wash the breather in a clean nonflammable solvent 6 Shake the breather until the breather is dry You may also use pressure air to dry the breather 7 Check the condition of the hose Replace the hose if the hose is damaged 8 Install the breather 9 Install the hose and the breather outlet hose clamps 10 Repeat Step 2 to Step 9
77. not in alignment the rubber seal between the outer ring and the hub has separated from the outer ring or from the hub Install a new vibration damper if the marks are not in alignment Note Contact your Caterpillar dealer for further information 101922370 Cutting Edges and End Bits Inspect Replace SMCS Code 6801 040 6801 510 6804 040 6804 510 S N 6PR1 Up S N 7KR1 Up Personal injury or death can result if the bowl is not blocked up Block the bowl before changing cutting edge NOTICE Do not attempt to increase wear life by welding on cutting edges This may result in premature failures Change or rotate the cutting edges or router bits be fore the mounting surfaces become worn fe 875806 Illustration 191 900 1 Raise the bowl and block up the bowl Only block up the bowl to a sufficient height for the removal of the cutting edges g00102101 Illustration 192 2 Remove the bolt 1 and pin assembly 2 g00102104 Illustration 193 3 Raise the apron high enough so that the apron passes over the pin holder 4 Install the pin assembly 5 Lower the apron until the apron is resting on the pin assembly 109 Maintenance Section Differential Thrust Pin Clearance Check Illustration 194 g00102105 6 Remove the bolts from the cutting edges Then remove the cutting edges 7 Clean the contact surfaces 8 Rotate the cutting edges If the op
78. olant level stabilizes 9 Maintain the coolant level at the bottom of the filler pipe so that the sight gauge is completely covered 10 Inspect the gasket of the cooling system pressure cap If the gasket is damaged replace the gasket 11 Install the cooling system pressure cap 12 Stop the engine 105 Maintenance Section Cooling System Coolant Extender ELC Add 101921796 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL When a Caterpillar Extended Life Coolant ELC is used an extender must be added to the cooling system See the Operation and Maintenance Manual Maintenance Interval Schedule for the proper service interval The amount of extender is determined by the cooling system capacity Table 7 Amount of Caterpillar Extender ELC Recommended Amount of Caterpillar Extender Cooling System Capacity 22 to 30 L 6 to 8 US gal 0 57 L 20 oz 31 to 38 L 8 to 10 US gal 0 71 L 24 oz 39 to 49 L 10 to 13 US gal 0 95 L 32 02 50 to 64 L 13 to 17 US gal 1 18 L 40 oz 65 to 83 L 17 to 22 US gal 1 60 L 54 oz 84 to 114 L 22 to 30 US gal 2 15 L 72 oz 115 to 163 L 30 to 43 US gal 164 to 242 L 43 to 64 US gal 3 00 L 100 oz 4 40 L 148 oz Note For cooling systems with larger capacities use the formula in Table 8 in order to determine the correct amount of extender Table 8 Calculation of ELC Extender Vv
79. pecial Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 253 g00103948 Before you replace the secondary filters replace the primary filter The secondary filters are behind the access door on the right side of the machine 1 Close the fuel supply valve The fuel supply valve is located behind the primary filter for the fuel system 2 Remove the secondary filters Discard the filters properly 3 Clean the filter housing base Make sure that all of the old seal is removed 4 Coat the seals of the new secondary filters with clean diesel fuel 133 Maintenance Section Fuel System Secondary Filter Replace 5 Install the new filters by hand When the seal contacts the base tighten the filter for an additional 3 4 turn Rotation index marks are positioned on the filters at 90 degree intervals Use these rotation index marks as a guide when you tighten the filter 6 Open the fuel supply valve 7 Prime the fuel system See Operation and Maintenance Fuel System Prime 8 Start the engine and check for leaks 101699584 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE S N 6PR1 Up S N 7KR1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection
80. peed control to the NEUTRAL position Engage the parking brake Inspect the transmission for leaks g00103194 Illustration 299 22 Maintain the oil level between the FULL and ADD OIL marks on dipstick 1 Add the oil through filler tube 2 if necessary 23 Stop the engine 101704743 Transmission Oil Filter and Magnetic Screen Replace Clean SMCS Code 3030 070 MGS 3067 510 S N 6PR1 Up S N 7KR1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates g00877370 Illustration 300 The transmission oil filter housing 1 is located on the left side of the transmission case The transmission oil filter housing is located at the left rear of the scraper engine 1 Park the machine on level ground Apply the parking brake Lower the bowl 2 Clean the filter housing 3 Remove the transmission filter housing drain plug 2 Allow the oil to drain into a suitable container 4 Remove transmission filter
81. posite sides of the cutting edges are not worn install the opposite sides of the cutting edges outward Note The cutting edges on the ends can be moved from one side of the machine to the other side of the machine if the cutting edges are not worn 9 Install new cutting edge sections if the cutting edges are worn on both sides 10 Install the bolts for the cutting edges and tighten the bolts to the specified torque Refer to Specifications SENR3130 Torque Specification 11 Raise the apron and remove the pin assembly from the pin holder Lower the apron and return the pin assembly to the pin s storage location 12 Raise the bowl and remove the blocking Lower the bowl to the ground 13 After a few hours of operation check the bolts for proper torque Tighten the bolts if necessary 101704843 Differential Thrust Pin Clearance Check SMCS Code 3258 535 T9 S N 5YR1 Up S N 6TR1 Up g00102131 Illustration 195 Refer to the Service Manual for the correct procedure to adjust the differential thrust pin or contact your Caterpillar Dealer Differential and Final Drive Breather Clean SMCS Code 3258 070 BRE 4050 070 BRE Illustration 196 g00102106 Tractor 1 The differential and final drive breather is located on the left side of the transmission at the rear of the tractor 110 Maintenance Section Differential and Final Drive Oil Change g00875921 Illustration 1
82. r elements 3 with a strap type wrench Refer to Operation and Maintenance Manual Oil Filter Inspect Clean the filter mounting base with a clean towel Make sure that the old filter gasket has been removed Apply a thin film of clean engine oil to the sealing surface of the new filter element Install the new filter elements hand tight When the gasket contacts the filter base turn the filter by 270 degrees more This will tighten the filter sufficiently 123 Maintenance Section Engine Oil High Speed and Oil Filter Change 8 Every new oil filter has marks which are for determining the rotation index These marks are spaced at 90 degree increments Use the rotation index marks as a guide for tightening the oil filter 9 Pump new oil into the engine See the following topics e Operation and Maintenance Manual Lubricant Viscositites e Operation and Maintenance Manual Capacities Refill 10 Remove the hose from the male coupler Install the dust cover 11 Start the engine and allow the oil to warm Check the engine for leaks Check the male fitting for leaks Check the filter for leaks Shut off the engine 12 Check the oil level on the dipstick 2 Maintain the oil between the marks on the SAFE OPERATING RANGE side of the dipstick If necessary add oil 101697868 Engine Oil High Speed and Oil Filter Change SMCS Code 1318 510 HZ S N 6PR1 Up S N 7KR1 Up
83. r the air filter housing 5 Install a clean primary air filter element Install the cover for the air filter housing Note Refer to Cleaning Primary Air Filter Elements 6 Reset the engine air filter service indicator If the yellow piston in the indicator moves into the red zone after starting the engine or the exhaust smoke is still black after installation of a clean primary filter element install a new primary filter element If the piston remains in the red zone replace the secondary element 117 Maintenance Section Engine Air Filter Primary Element Clean Replace Cleaning Primary Air Filter Elements NOTICE Caterpillar recommends certified air filter cleaning ser vices available at participating Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life Observe the following guidelines if you attempt to clean the filter element Do not tap or strike the filter element in order to remove dust Do not wash the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must not exceed 207 kPa 80 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine componen
84. r vertical hitch pin if shafts for wear or for damage Replace the shafts necessary in the steering link if necessary i00061636 Hitch Lubricate SMCS Code 7107 086 7113 086 Wipe all of the fittings before you inject grease into the fittings Illustration 261 g00102798 Inspect the lower vertical hitch pin for wear or damage Replace the lower vertical hitch pin if necessary Consult your Caterpillar Dealer for the allowable tolerance of all the vertical hitch pins g00102815 Illustration 264 Inject the grease into 34 fittings that are located on the lube fitting block These fittings provide lubrication to the joint assembly in front of the vertical hitch pins Note If any remote lines are damaged replace the damaged remote lines Fill the new remote lines with grease Wee Ua J 101699826 Illustration 262 900102799 Hydraulic System Oil Change Inspect the two horizontal hitch pins for wear or SMCS Code 5056 044 for damage Replace the horizontal hitch pins if necessary NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to co
85. rain 2 i01699603 Fuel System Water Separator Drain SMCS Code 1263 543 S N 6PR1 Up S N 7KR1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates g00874997 Illustration 256 The fuel system water separator is located on the left rear side of the scraper below the primary fuel filter 1 Open drain 2 on water separator bowl 1 2 Drain the water from water separator bowl 1 Close the drain 2 135 Maintenance Section Fuel Tank Cap and Strainer Clean 100842136 Fuel Tank Cap and Strainer Clean SMCS Code 1273 070 STR 1273 070 Z2 The fuel tank cap is located on the top of the fuel tank The fuel cap has a filter element that is located within the cap The filter element filters the air that enters the fuel tank as the fuel level changes The strainer is located under the fuel cap The strainer will strain the fuel as the fuel enters the fuel tank 1 Remove the fuel tank cap 2 Remove the gask
86. s Dispose of all fluids according to local regulations and mandates Illustration 268 g00102885 1 Remove the oil filler cap slowly in order to relieve the tank pressure g00102893 Illustration 269 2 Remove the filter cover 3 Inspect the cover seal Replace the cover seal if necessary 4 Remove the filter elements and discard the filter elements 5 Remove the screen Wash the screen in clean nonflammable solvent 6 Install the screen and two new filter elements 7 Install the filter cover g00102913 Illustration 270 8 Maintain the oil level above the ADD mark in the sight gauge Add oil if necessary 9 Inspect the filler cap gasket Replace the filler cap gasket if the filler cap gasket is damaged 10 Install the oil filler cap 140 Maintenance Section Hydraulic System Oil Level Check i01699861 Hydraulic System Oil Level Check SMCS Code 5050 535 FLV S N 5YR1 Up S N 6TR1 Up g00875178 Illustration 271 The hydraulic tank is located at the rear of the tractor Clean the sight gauge 1 in order to view the oil level Note The machine must meet the following conditions before you check the hydraulic tank oil level e The machine must be level e The parking brake must be applied e The hydraulic oil must be warm e The engine must be running at low idle e The transmission control must be in NEUTRAL e The cushion hitch must be in the O
87. tain SMCS Code 1395 554 S N 6PR1 Up S N 7KR1 Up g00875297 Illustration 181 The cooling system is not equipped with a sampling valve Obtaining a sample of the cooling system will require a vacuum pump or an equivalent Withdraw the fluid through the cooling system pressure cap For additional information about coolant analysis refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 103 Maintenance Section Cooling System Coolant ELC Change 101925972 Cooling System Coolant ELC Change SMCS Code 1350 044 NL S N 5YR1 Up S N 6TR1 Up NOTICE Do not change the coolant until you read and under stand the cooling system information in Special Pub lication SEBU6250 Caterpillar Machine Fluids Rec ommendations Failure to do so could result in damage to the cooling system components NOTICE Mixing ELC with other products reduces the effective ness of the coolant and shortens coolant life Use on ly Caterpillar products or commercial products that have passed the Caterpillar EC 1 specifications for premixed or concentrate coolants Use only Caterpillar Extender with Caterpillar ELC Failure to follow these recommendations could result in the damage to cool ing systems components If ELC cooling system contamination occurs see the topic Extended Life Coolant ELC in the Special Pub lication SEBU6250 Caterp
88. te asni eee entire 130 Hydraulic System Oil Sample Obtain 141 Transmission Oil Sample Obtain 154 Transmission Oil Sample Obtain 0 155 Every 500 Service Hours or 3 Months Accumulator Cushion Hitch Check 00 92 Brake Camshaft Bearing Lubricate 0 97 Cooling System Coolant Sample Obtain 102 Cooling System Coolant Sample Obtain 102 Differential and Final Drive Oil Sample Obtain 112 Engine Crankcase Breather Clean 0 05 121 Engine Crankcase Breather Clean 05 121 Fuel System Secondary Filter Replace 132 Fuel System Secondary Filter Replace 133 Fuel Tank Cap and Strainer Clean 0 135 Hydraulic System Oil Filter Replace 139 Steering Pump Outlet Screen Clean 145 Transmission Oil Filter and Magnetic Screen Replace Clean cscccccceeeseeesseeeeeseeseneeessneeeeaes 151 Transmission Oil Filter and Magnetic Screen Replace Clean cscccccceeeseeeeseeeeeeeeseneeeseneeeeaes 152 Every 1000 Service Hours or 6 Months Brake Air System Warning Horn Test 00 97 Differential and Final Drive Breather Clean 109 Rollover Protective Structure ROPS Inspect 143 Suction Screen Transmission Scavenge CICA nepra a Aea aE 146 91 Maintenance Section Maintenance Interval Schedule Transmission Breather Cl
89. th of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the primary air filter element Dirt could be forced further into the pleats Vacuum Cleaning Vacuum cleaning is another method for cleaning primary air filter elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil 118 Maintenance Section Engine Air Filter Secondary Element Replace Inspecting the Primary Air Filter Elements Illustration 223 g00281693 Inspect the clean dry primary air filter element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the primary air filter element Rotate the primary air filter element Inspect the primary air filter element for tears and or holes Inspect the primary air filter element for light that may show through the filter material If it is necessary in order to confirm the result compare the primary air filter element to a new primary air filter element that has the same part number Do not use a primary air filter element that has any tears and or holes in the filter material Do not use a primary air filter element with damaged pleats gaskets or seals Discard damaged primary air filter elements Storing Primary Air Filter Elements If a primary air filter element that passes
90. that no people or obstacles are in the area around the machine Test the brakes on a dry level surface Fasten the seat belt before you test the brakes This test is not intended to measure the maximum brake holding effort The brake holding effort that is required to hold a machine at a specific engine rom will be different for various machines This is due to variances in the engine setting in the power train efficiency and in the brake holding ability When the machine begins to move the engine rom should be compared to a prior test Use the comparison as an indication of system deterioration Illustration 173 g0087488 1 1 Start the engine and look at the air pressure gauge Allow the brake system air pressure to reach 850 50 kPa 125 10 psi 2 Raise the bowl slightly Illustration 174 g00872565 3 While the parking brake is applied move the transmission direction and speed control to second speed g00870481 Illustration 175 4 Gradually increase the engine speed to high idle The machine should not move when the engine rom is at 1000 100 rpm The engine rom should be 1000 100 rom or more Record the actual engine rpm that is achieved during the test for future comparisons If the engine rpm is less than 900 rpm consult your Caterpillar Dealer for an inspection of the machine and for repairs of the machine 5 Reduce the engine speed and move the transmission direction and spee
91. the terminals of the battery 5 Perform the necessary repairs Replace the cable or the battery as needed 6 Connect the negative battery cable to the terminals of the battery 95 Maintenance Section Belt Inspect Adjust Replace 7 Connect the negative battery cable at the battery disconnect switch 8 Install the key for the battery disconnect switch Turn the key to the ON position i01698702 Belt Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 1397 025 1397 040 1397 510 Inspect the belts for cracks Inspect the belts for missing pieces Inspect the belts for frayed areas Inspect the belts for wear A worn belt will ride in the bottom of the pulley Replace the belts if any of these conditions exist Replace the belts if the belts are stretched beyond the limits of the adjuster Note If new belts are installed recheck the belt adjustment after 30 minutes of operation If two belts or more are required for an application replace the belts in belt sets that are matched If only one belt of a matched set needs replacement replace all of the belts in the set Belts of the same part number are not necessarily matched belts Fan Drive Belts Note The fan drive belts for the scraper are adjusted in the same manner as the tractor AZ Illustration 159 g00101052 The fan drive belts are located in the engine compartment of the tractor Open the access door on the right side of the eng
92. ts The primary air filter element can be used up to six times if the element is properly cleaned and inspected When the primary air filter element is cleaned check for rips or tears in the filter material The primary air filter element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings NOTICE Do not clean the air filter 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 Engine damage could result Visually inspect the primary air filter elements before cleaning Inspect the air filter elements for damage to the seal the gaskets and the outer cover Discard any damaged air filter elements There are two common methods that are used to clean primary air filter elements e Pressurized air e Vacuum cleaning Pressurized Air Pressurized air can be used to clean primary air filter elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 222 g00281692 Note When the primary air filter elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside Aim the hose so that the air flows inside the element along the leng
93. urbocharger Inspect esseere 155 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 105 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 103 Cooling System Coolant ELC Change 104 92 Maintenance Section Accumulator Cushion Hitch Check 101823375 Accumulator Cushion Hitch Check SMCS Code 5077 535 S N 5YR1 Up S N 6TR1 Up Illustration 152 g00866922 Check the precharge pressure in the cushion hitch accumulators Add nitrogen if necessary Consult your Caterpillar Dealer for the checking procedure for the filling procedure and for the recommended precharge pressure i00058661 Air Dryer Check SMCS Code 4285 535 S N 5YR1 Up S N 6TR1 Up g00101047 Illustration 153 1 Open the drain valve for the air reservoir 2 Check for moisture in the air reservoirs Close the drain valve for the air reservoir Illustration 154 g00101048 3 If there is moisture in the air reservoirs replace the air dryer desiccant cartridge or rebuild the desiccant cartridge Consult your Caterpillar Dealer for information about replacing the air dryer desiccant cartridge and for instructions for rebuilding the air dryer desiccant cartridge Note Small amounts of moisture may be in the system due to condensation in the system Moisture may also be in the system if an air dryer is installed on a machine that has bee
94. will settle to the bottom of the crankcase The particles will not be removed by draining the oil and the particles will recirculate in the engine lubrication system with the new oil 1 Park the machine on a level surface and engage the parking brake Stop the engine g00102392 Illustration 242 2 Remove the drain plug through the access hole 3 Allow the oil to drain into a suitable container 4 Close the crankcase drain valve Install the drain plug 5 Open the access door on the right side of the engine 6 Remove the oil filter 3 with a strap type wrench See Operation and Maintenance Manual Oil Filter Inspect Discard the used oil filter properly 127 Maintenance Section Engine Oil and Filter Change 7 Clean the filter housing base Make sure that all of the old filter gasket is removed 8 Apply a thin coat of engine oil to the gasket of the new filter 9 Install the new filter by hand When the gasket contacts the filter base turn the filter by 270 degrees more This will tighten the filter sufficiently 10 Every new oil filter has marks which are for determining the rotation index These marks are spaced at 90 degree increments Use the rotation index marks as a guide for tightening the oil filter 11 Remove oil filler cap 1 Fill the crankcase with new oil See Operation and Maintenance Manual Capacities Refill Clean oil filler cap 1 and install oil filler cap 1
95. x 0 02 X2 1 V is the total volume of the cooling system 2 X is the amount of ELC Extender that is required For additional information about adding an extender see Special Publication SEBU6250 Extended Life Coolant ELC or consult your Caterpillar Dealer 101924947 Cooling System Coolant Level Check SMCS Code 1350 535 FLV The cooling system pressure cap is located on the top of the hood at the front of the machine Illustration 184 Tractor fs Illustration 185 g00875297 Scraper 1 Remove the cooling system pressure cap slowly in order to relieve the pressure 2 Maintain the coolant level at 13 mm 5 inch from the bottom of the filler pipe If it is necessary to add coolant daily check the system for leaks 3 If additional coolant is necessary remove the cooling system pressure cap and add the appropriate coolant mixture Install the pressure cap 106 Maintenance Section Cooling System Pressure Cap Clean Replace i01700466 Cooling System Pressure Cap Clean Replace SMCS Code 1382 070 1382 510 Illustration 186 Tractor g00875297 Illustration 187 Scraper 1 Remove the cooling system pressure cap slowly in order to relieve the pressure 2 Inspect the cap for damage for foreign material and for deposits 3 Clean the cap with a clean cloth or replace the cap if necessary 4 Inspect the condition of the gasket in t

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