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MAINTENANCE INTERVALS - Safety

1. EIS ISI zs ILL IL e Illustration 151 902044873 Center plate TER E m 0 n 0 Illustration 152 Left plate g02044874 g02044875 Illustration 153 Right plate In order to lubricate the auger slide use the following procedure 1 Lower the auger slide to the lowest position 2 Lubricate the auger slide with a line of grease at the indicated positions Note Make sure that you lubricate all three locations 3 Raise the auger slide and lower the auger slide in order to spread the grease 116 Maintenance Section Backup Alarm Test KEBU7046 103786312 Backup Alarm Test SMCS Code 7406 081 o d y ze 5 oe eel ejsfelele o fio 4E ere slee Illustration 154 e MIO 7 902044896 Start the engine and run the engine at low idle Turn speed potentiometer 1 to the lowest setting Make sure that the area behind the machine is clear of personnel and clear of obstacles Slightly move propel lever 2 to the REVERSE position The backup al
2. Illustration 243 g02054414 There are three lubrication points on each side of the machine There are a total of six lubrication points on the machine Pump grease into the fittings 1 until resistance is felt 103797975 Track Takeup Linkage Lubricate SMCS Code 4157 086 KL Illustration 244 902054454 There are four grease fittings There are two grease fittings on each set of linkage There is one set of linkages on each side of the machine Clean the fittings before you lubricate the linkage Add the lubricant until a small amount of lubricant is observed at the linkage KEBU7046 151 Maintenance Section Track Tension Check Note You must remove the plugs and you must install grease fittings in order to lubricate the linkage Note Lubricate the fittings when the track has been removed from the machine for service 103798029 Track Tension Check SMCS Code 4170 535 T7 Illustration 245 g02054495 Note The track tension system is a closed system after the tension has been set The track has tension from the closed system at all times Check the track in order to determine if the track is loose or if the track is tight If the track is loose refer to the service manual for the correct procedure for tensioning the track 103799330 Truck Hitch Lubricate
3. 146 KEBU7046 Maintenance Section Pump Drive Oil Level Check 3 Dispose of the oil in a proper manner xs d 2 2 9 Sw A icu 5 Sem o a cds E m S T ui 5 WF g02111616 902055061 Illustration 228 902055059 4 Remove plug 3 in order to fill the pump drive with oil Remove the breather 2 See the Operation and Maintenance Manual Pump Drive Breather Clean for cleaning instructions 5 Fill the gearbox See the Operation and Maintenance Manual Capacities Refill for the amount of oil that is needed in order to fill the gearbox Illustration 230 6 Check the oil level with oil level gauge 4 The oil level can also be viewed through sight gauge 5 on the pump drive which can be seen through the access doors in the hopper 7 Maintain the pump drive oil level on oil level gauge 4 between the FULL mark and the ADD mark 8 Clean the breather and install the breather 2 9 Clean the plug and install the plug 3 103799255 Pump Drive Oil Level Check SMCS Code 3108 535 FLV NOTICE Caterpillar recommends obtaining an oil sample and performing a SOS Oil Analysis at regular intervals to help prevent damage to components Use the infor mation in Sampling Interval and Location of the Sam pling Valve in this OMM to find the proper sampling interval for your machine 902055760 Illustration 229
4. ESSEN By Illustration 260 g00864096 Nuts 1 may become loose under normal operating conditions Tighten nuts 1 to a torque of 560 60 N m 413 44 Ib ft
5. 5 Install the hose Tighten the hose clamp 1 6 Inspect pressure cap and the gasket for damage Replace the pressure cap if the pressure cap or the gasket are damaged 7 Install the water temperature regulator housing 3 Install the two bolts 2 8 Add the cooling system coolant Maintain the coolant level to the top of the filler tube 9 Close all access doors and lock the access doors 103790052 Drag Conveyors Adjust SMCS Code 6630 025 Illustration 183 901358509 1 Drag conveyor 2 Supports 3 Roller 4 Side Plate 5 Conveyor s Support In order to adjust the drag conveyor 1 to the proper tension use the side plate 4 as a reference The drag conveyor 1 should hang approximately 1 27 cm 0 5 inch above the edge of the side plate 4 There are two supports 5 along the length of the drag conveyor Perform the following steps in order to tighten or loosen the drag conveyor g02047733 Illustration 184 6 Adjusting rod 7 Cotter pin 8 Front takeup shaft 1 Remove cotter pin 7 from adjusting rod 6 2 Remove adjusting rod from front takeup shaft 6 3 Insert the adjusting rod 6 into the holes of front takeup shaft 8 in order to adjust the drag chain Adjust the front takeup shaft in small increments Turn the front takeup shaft counterclockwise in order to tighten the drag chain Turn the front takeup sha
6. There are two ways to measure the wear of a drag pan Ultrasonic Measurement 1 Use an ultrasonic gauge in order to measure the thickness of the drag pans New drag pans have a thickness of 12 7 mm 0 5 inch Once the pans are worn to a thickness of 3 175 mm 0 125 inch the drag pans need to be replaced 2 Take the measurement at the center of the drag pan The center is the thinnest part of the drag pan You may need to alternate replacing the middle pans due to wear patterns Inspection of the Hardware Illustration 174 900861346 The drag pans should be replaced when an allen wrench can no longer be inserted into the bolt At this point the bolts are no longer countersunk and the bolt heads have begun to wear Note If the drag pans are worn to approximately 8 5 mm 0 333 inch you must make a decision If the drag pans have been used for two years the pans will probably last for another year of similar use If the drag pans have only been used for one year the pans should be replaced in order to avoid replacing the pans during paving season This decision involves some discretion 103789931 Cooling System Coolant ELC Change SMCS Code 1350 044 NL Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns
7. 0 0 00 ee 115 Battery Recycle eese 116 Battery or Battery Cable Inspect Replace 116 Engine Air Cleaner Inlet Clean 129 Engine Air Filter Primary Element Clean Replace nbn DER eto ee 129 Engine Air Filter Secondary Element Replace 130 Fuel System Prime ssseseeeeee 134 Fuses Replace ssssssssee 138 Hopper Flashing Inspect Replace 143 Oil Filter Inspect sssssessesesse 145 Ventilation Blower Wheel Inspect Clean 152 Every 4 Service Hours or Twice Daily Auger Conveyors Lubricate sssssse 114 Drag Conveyors Lubricate ssss 128 Truck Hitch Lubricate sesesssssss 151 Every 10 Service Hours or Daily Backup Alarm Test c eeseeeeeceeeeeeeteeeeeeeeees 116 Cooling System Coolant Level Check 126 Engine Air Filter Service Indicator Inspect 130 Engine Oil Level Check sssssss 131 Fuel System Water Separator Drain 137 Fuel Tank Water and Sediment Drain 138 Hydraulic System Oil Level Check 143 Idler Wheel Takeup Inspect 144 Pump Drive Oil Level Check 146 Seat Belt Inspect ssssessssssssss 148 Conve
8. SMCS Code 6654 040 BW 6654 070 BW Perform the following steps in order to clean the blower wheel and inspect the blower wheel for the ventilation system g02105861 Illustration 248 1 Remove the four bolts 1 and washers 2 Remove the exhaust stack KEBU7046 153 Maintenance Section Ventilation Blower Wheel Inspect Clean Illustration 250 902105866 3 Remove the five bolts 2 and the washers that are visible in the bottom of the ventilation system duct after the exhaust stack is removed 902105876 Illustration 251 4 Open access cover 3 Illustration 252 902105877 5 Remove the two bolts 4 and the washers 6 Remove bracket 5 Illustration 253 902105893 7 Remove the two bolts 6 and washers g02105913 Illustration 254 8 Remove the hose for the pitot tube from the back of manometer 7 154 Maintenance Section Ventilation Inlet Ducts Inspect Clean KEBU7046 Illustration 255 9 Open access door 8 Illustration 256 902105935 10 Remove the two bolts 9 and washers 11 Remove ventilation duct 10 902105953 Illustration 257 12 Inspect blower wheel 11 for damage Clean the wheel with nonflammable solvent Dry the wheel Replace the wheel if the wheel is damaged Inspect the hydraulic motor If necessary re
9. Fill the final drive planetary Allow the machine to sit for 45 minutes Reference Refer to Operation and Maintenance Manual Capacities Refill for the correct refill capacity 134 Maintenance Section Final Drive Planetary Oil Level Check KEBU7046 Note The machine needs to sit for 45 minutes in order to fill the rear bearings of the final drive planetary Failure to wait for 45 minutes may result in bearing failure 4 Fill the planetary with oil up to plug 2 5 Clean plug 1 and install the plug 103792775 Final Drive Planetary Oil Level Check SMCS Code 4050 535 FLV g02050075 Illustration 199 The final drive planetary is located at the rear of each track assembly There is one final drive on each side of the machine Check the oil level of each drive Note The final drives have three plugs Position the final drive with plug 1 at the top of the drive Plug 2 is used to check the level of the oil in the drive Remove the oil level check plug 2 The oil level should be at the bottom of the opening for the oil level check plug Remove plug 1 in order to fill the drive Clean the plugs and install the plugs 103792779 Final Drive Planetary Oil Sample Obtain SMCS Code 4050 008 7542 008 Illustration 200 902050079 Refer to Special Publication SEBU6250 S O S Oil Analysis f
10. Illustration 231 902055773 KEBU7046 147 Maintenance Section Pump Drive Oil Sample Obtain zo M ETE 103799270 Pump Drive Oil Sample Obtain SMCS Code 3108 008 7542 008 Illustration 232 902111609 1 Check the oil level with oil level gauge 1 The oil level can also be viewed through sight gauge 2 on the pump drive which can be seen through the access doors in the hopper Note 2 Maintain the pump drive oil level on oil level gauge 1 between the FULL mark and the ADD mark E Illustration 233 902055793 3 If oil needs to be added remove the plug 3 for the fill port Add oil through the opening 4 Clean the plug 3 and install the plug 3 g02055056 Illustration 234 1 Clean the end of drain hose 1 and the cap Remove the cap from the drain hose Drain a small amount of oil into a suitable container 2 Obtain a sample of the oil in a suitable container 3 Send the oil sample to your dealer for analysis 4 Check the level of the oil in the gearbox If necessary add oil 103625928 Radiator Core Clean SMCS Code 1353 070 KO Make sure that the engine shutdown switch is in the OFF position Do not clean the radiator core when the machine is running Illustration 235 900101939 148 Maintenance Section Seat Belt Inspect KEBU7046 Inspect the radiator core for debris If necessary clean the
11. Oil Sample Obtain 144 Pump Drive Oil Change sesessss 145 Pump Drive Oil Sample Obtain 147 Every 500 Service Hours or 3 Months Cooling System Coolant Sample Level 1 Obtalli itio inu Rer 125 Every 500 Service Hours or 6 Months Braking System Test ssssssssssss 117 Every 1000 Service Hours Hydraulic System Oil and Filters Change 143 Pump Drive Breather Clean 145 Track Roller Bearings Inspect 150 Track Takeup Linkage Lubricate 150 Every 1000 Service Hours or 1 Year Engine Valve Lash Check ssssss 133 Every 2000 Service Hours Alternator Inspect ssssssseesese 114 Engine Mounts Inspect assises 131 Track Roller Bearings Lubricate 150 Turbocharger Inspect n se 151 Every Year Cooling System Coolant Sample Level 2 Obtaln oS enne eee s 126 Every 3000 Service Hours Cooling System Water Temperature Regulator Replaces aient Rr odd 127 Every 3000 Service Hours or 2 Years Starting Motor Inspect ieies 148 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace sssssssesssssss 148 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 125 Every 12 000 Servic
12. information about obtaining a sample of the hydraulic oil 102747547 Idler Bearings Takeup Lubricate SMCS Code 4159 086 BD Illustration 222 g01376247 There are two idlers on each side of the track There is a fitting in the middle of each of the four idlers Apply grease to the four idlers Apply grease until excess grease is observed from the grease relief fitting on the inside part of the idler hub 102747558 Idler Wheel Takeup Inspect SMCS Code 4159 Illustration 223 901376253 Check idler rims and track roller rims for damage Notify your dealer if damaged rims are observed Damaged rims may cause damage to the track Damaged rims may cause improper track movement KEBU7046 145 Maintenance Section Oil Filter Inspect 102106227 Oil Filter Inspect SMCS Code 1308 507 3004 507 5068 507 Inspect a Used Filter for Debris Illustration 224 900100013 The element is shown with debris Use a 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
13. side of the machine The top grease fitting for each cylinder can be accessed through the radiator access cover The lower grease fittings can be accessed through the side access doors KEBU7046 143 Maintenance Section Hopper Flashing Inspect Replace 103356040 Hopper Flashing Inspect Replace SMCS Code 6639 040 FK 6639 510 FK 901730235 Illustration 217 Inspect the front hopper flashing for deterioration Hot asphalt and trucks that are delivering the asphalt to the machine can damage the hopper flashing If necessary repair the hopper flashing Hopper flashing that is not repaired or replaced can cause excess spillage of asphalt in front of the machine 103793826 Hydraulic System Oil Level Check SMCS Code 5056 535 FLV fl A g02051094 Illustration 218 1 Check the hydraulic oil level with oil level gauge 1 2 Maintain the oil level between the FULL mark and the ADD mark 3 Add additional oil if the oil level is below the ADD mark 4 Check filler cap 2 Replace the filler cap if the filler cap is damaged 5 Install the filler cap 2 103793862 Hydraulic System Oil and Filters Change SMCS Code 5056 044 5068 510 902051154 Hydraulic Tank Cap 2 3 4 Hydraulic Oil Level Gauge 5 Return Filter 1 Remove hydraulic tank cap 3 in order to relieve pressure from the hydraulic system T4 E g02
14. the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Illustration 179 902047634 Refer to the Operation and Maintenance Manual Access Doors and Covers for the location of the service points Obtain the sample of the coolant as close as possible to the recommended sampling interval Supplies for collecting samples can be obtained from your Caterpillar dealer Refer to Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 103790009 Cooling System Coolant Level Check SMCS Code 1350 535 FLV At operating temperature the engine coolant is hot and under pressure Steam can cause personal injury Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand Remove the fill cap slowly to relieve pressure Cooling system conditioner contains alkali Avoid contact with the skin and eyes to prevent personal injury Illustration 180 902047634 1 Slowly loosen the filler
15. 046 141 Maintenance Section Ground Fault Check g02102139 Illustration 211 Remove the top cover of the generator in order to clean the generator Periodically generators should be inspected for cleanliness The following contaminants should not be allowed to accumulate on the windings e dirt e dust grease e salt e Oil film If moisture is allowed to remain in contact with an electrical winding some of the moisture will eventually be retained in voids or cracks of the insulation This will lower the resistance of the winding insulation The insulation that is used on the windings of Caterpillar generators is moisture resistant However constant exposure to moisture will gradually lower the insulation s resistance Dirt can make the problem worse Dirt can hold moisture in contact with the insulation The salt that is present in sea air can compound the problem When salt and moisture combine a good electrical conductor is created Clean the voltage regulator and clean the generator of dirt and debris Use a brush to loosen accumulations of dirt Vacuum clean the system in order to remove residual dirt The use of compressed air is not recommended Compressed air contains moisture that is present in the form of condensation Carbon tracking on insulators can be caused by dirt or carbon tracking on insulators can be caused by loose connections These carbon paths must be cleaned or the insulators mus
16. 051167 Illustration 220 2 Remove drain plug 6 and install the 134 8474 drain hose Drain the hydraulic oil into a suitable container Note Refer to Operation and Maintenance Manual General Hazard Information for information on containing fluid spillage 144 Maintenance Section Hydraulic System Oil Sample Obtain KEBU7046 3 Remove the cover for the charge filter 1 Remove the charge filter 4 Remove the return filter cover 5 Remove the return filter 5 Remove the drain hose and Install drain plug 6 6 Install a new charge filter Install the cover for the charge filter 1 T Install a new return filter Install the return filter cover 5 8 Fill the hydraulic tank Refer to the Operation and Maintenance Manual Capacities Refill for the correct refill capacity 9 Replace hydraulic tank cap 3 10 Start the engine Run the engine for a few minutes Check the hydraulic filters for leaks 11 Stop the engine 12 Repair the leaks that were found 13 Maintain the oil between the FULL and ADD marks on oil level gauge 4 103793958 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 7542 008 902051235 Illustration 221 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
17. 6 Fuel System Third Filter Replace 137 Idler Bearings Takeup Lubricate 144 Radiator Core Clean sssseeeess 147 Toggle Switch Inspect esssesss 149 Tracks Inspect sssssssssssssssesesee 149 Track Tension Check sessssessss 151 Ventilation Blower Wheel Inspect Clean 152 Every 250 Service Hours or Monthly Ground Fault Check ssssssssssss 141 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 OBA 22 he PEPEE EEE S LT E 126 Every 500 Service Hours Conveyor Planetary Drive Auger Oil Change 119 KEBU7046 113 Maintenance Section Maintenance Interval Schedule Conveyor Planetary Drive Auger Oil Sample ODA evene einn 120 Conveyor Planetary Drive Drag Oil Change 120 Conveyor Planetary Drive Drag Oil Sample OBTAIN 2 tne eee ee ded 121 Conveyor System Inspect ssusss 121 Engine Crankcase Breather Clean 131 Engine Oil and Filter Change 132 Final Drive Planetary Oil Change 133 Final Drive Planetary Oil Sample Obtain 134 Fuel Tank Cap Filter and Strainer Clean Inspect Replace ssssssss 138 Generator Clean see 140 Hydraulic System
18. Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component H I Gi Illustration 202 902054373 1 Place a container under the fuel filter 1 before you remove the filter Note Refer to Operation and Maintenance Manual General Hazard Information for information on containing fluid spillage 2 Remove the fuel filter 1 3 Clean the filter of any debris 4 Reinstall the filter 103793599 Fuel System Primary Filter Clean Inspect Replace SMCS Code 1260 510 1260 571 Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component NOTICE Do not use a tool in order to remove the fuel filter Attempting to remove the fuel filter with a filter wrench or a filter strap could damage the locking ring Illustration 203 902050833 1 Place a
19. If Equipped SMCS Code 7122 086 NOTICE All daily grease lubricant should be applied at the end of each machine operation while the asphalt is still warm and not set up Failure to do so may allow the asphalt to harden around the seals and risk damaging a seal leading to premature bearing failure Illustration 246 902055895 There are two roller bearings 1 for the truck hitch There is one bearing on each side of the truck hitch Lubricate each bearing There are two fittings 2 on the truck hitch system There is one fitting on each end of the assembly Lubricate each fitting There are two slide assemblies 3 on the truck hitch system There is one slide assembly on each end of the assembly Lubricate each slide assembly 103798103 Turbocharger Inspect SMCS Code 1052 040 g02054554 Illustration 247 Periodic inspection and cleaning is recommended for the turbocharger compressor housing inlet side Since the fumes from the crankcase are filtered through the air inlet system oil and combustion by products may collect in the turbocharger compressor housing Over time this buildup can contribute to loss of engine power increased black smoke and overall loss of engine efficiency This buildup is only a possible contributor to these factors 152 Maintenance Section Ventilation Blower Wheel Inspect Clean KEBU7046 If the turbocharger fails during engine operation damage to the
20. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved Q o KEBU7046 CATERPILLAR oran 2010 Operation and Maintenance Manual AP555E and BG555E Asphalt Pavers 112 KEBU7046 Maintenance Section Maintenance Interval Schedule i03786189 Ventilation Inlet Ducts Inspect Clean 154 Maintenance Interval Schedule Initial 50 Service Hours SMCS Code 7000 Conveyor Drive Chains Auger Adjust 118 Conveyor Drive Chains Drag Adjust 119 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Note Before each consecutive interval is performed all maintenance from the previous interval must be performed When Required Auger Slide Lubricate
21. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes 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 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 124 Maintenance Section Cooling System Coolant ELC Change KEBU7046 NOTICE Do not change the coolant until you read and under stand the material in the Cooling System Specifica tions section NOTICE Mixing Extended Life Coolant ELC with other prod ucts reduces the effectiveness of the coolant and shortens coolant life Use only Caterpillar prod ucts or commercial products that have passed the Caterpillar EC 1 specifications for premixed or con centrate coolants Use only Caterpillar Extender with Caterpillar ELC Failure to f
22. al 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 3 00 L 100 oz 164 to 242 L 43 to 64 US gal 4 40 L 148 oz Note For cooling systems with larger capacities use the formula in Table 14 in order to determine the correct amount of extender Table 14 Calculation of ELC Extender V x 0 02 XO 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 Operation and Maintenance Manual SEBU6250 Extended Life Coolant ELC or consult your Caterpillar Dealer 103789990 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 7542 008 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Note Level 1 results may indicate a need for Level 2 Analysis Illustration 178 902047634 Refer to the Operation and Maintenance Manual Access Doors and Covers for the location of the service points Obtain the sample of the coolant as close as possible to the recommended sampling inter
23. arm should sound immediately The backup alarm should continue to sound until propel control lever 2 is moved to the NEUTRAL position or to the FORWARD position The backup alarm is on the rear of the machine 100993589 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 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 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 103786330 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Inspect the Belts For ma
24. as been cleaned Replace the water temperature regulator while the cooling system is completely drained NOTICE Failure to replace the engine s water temperature reg ulator on a regularly scheduled basis could cause se vere engine damage Note If you are only replacing the water temperature regulator drain the cooling system coolant to a level that is below the water temperature regulator housing Illustration 182 902047694 Loosen hose clamp 1 and remove the hose from water temperature regulator housing 3 N Remove bolts 2 from the housing for the water temperature regulator Remove water temperature regulator housing 3 o Remove the gasket NOTICE The water temperature regulators may be 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 temperature regulator could result in either an over heating or an overcooling condition NOTICE If the water temperature regulator is installed incor rectly it will cause the engine to overheat 128 Maintenance Section Drag Conveyors Adjust KEBU7046 4 Install a new water temperature regulator and a new gasket
25. cap on the shunt tank in order to release any pressure in the system Slowly remove the filler cap on the shunt tank KEBU7046 127 Maintenance Section Cooling System Water Temperature Regulator Replace Illustration 181 901402853 The shunt tank is located inside the compartment to the left of the exhaust stack 2 Maintain the coolant level between the indicated lines If it is necessary to add coolant daily check the cooling system for leaks Repair the leaks as the leaks are found 3 Inspect the gasket Inspect the filler cap on the shunt tank Clean the filler cap on the shunt tank with a clean cloth Replace the cap if the gasket or the cap are damaged 4 Install the filler cap on the shunt tank Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 1393 010 At operating temperature the engine coolant is hot and under pressure Steam can cause personal injury Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand Remove the fill cap slowly to relieve pressure Cooling system conditioner contains alkali Avoid contact with the skin and eyes to prevent personal injury Replace the water temperature regulator on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system The water temperature regulator should be replaced after the cooling system h
26. chine Fuse The fuses protect the electrical NOTICE Replace the fuses with the same type and size only Otherwise electrical damage can result If it is necessary to replace fuses frequently an elec trical problem exists Contact your Caterpillar dealer KEBU7046 139 Maintenance Section Fuses Replace Primary Fuse Panel The primary fuse panel is located behind the access panel below the exhaust stack Illustration 209 992089996 Table 15 Primary Fuse Panel 1 2 3 4 5 Brake Lights Spare Switched Machine ECM Autolube Brake Lights 15A 15A 15A 15A Relay Glow Plugs Operator Control Parking Lights Spare Unswitched Left Turn Signal 20A 15A 20A 15A Relay Screed HID Lights Work Lights Right Turn Signal 25A 25A 20A Relay Limp Home Mode Travel Lights 12 V Power Supply Parking Lights 10A 20A 15A Relay Generator Slave ECM Spray Down Travel Lights 15A 15A 15A Relay Sensor Display Screed ECM Spray Down 10A 10A 15A Relay Grade Slope Horn Operator ECM Work Lights 15A 10A 15A Relay 140 Maintenance Section Generator Clean KEBU7046 Secondary Fuse Panel The secondary fuse panel is located behind the left side access door A B C D E F Illustration 210 902089557 Table 16 Secondary Fuse Panel A Starter Relay Fuse 60A B Starter Motor Fuse 30A C Main Power Relay Fuse 30A D Main Power Fuse 40A E G
27. e Hours or 6 Years Cooling System Coolant ELC Change 123 114 Maintenance Section Alternator Inspect KEBU7046 101664049 Alternator Inspect SMCS Code 1405 040 Caterpillar recommends a scheduled inspection of the alternator Inspect the alternator for loose connections and proper battery charging Inspect the ammeter if equipped during engine operation in order to ensure proper battery performance and or proper performance of the electrical system Make repairs as required Refer to the Service Manual Check the alternator and the battery charger for proper operation If the batteries are properly charged the ammeter reading should be very near zero All batteries should be kept charged The batteries should be kept warm because temperature affects the cranking power If the battery is too cold the battery will not crank the engine The battery will not crank the engine even if the engine is warm When the engine is not run for long periods of time or if the engine is run for short periods the batteries may not fully charge A battery with a low charge will freeze more easily than a battery with a full charge 103786197 Aftercooler Core Inspect Clean SMCS Code 1063 040 1064 571 a Illustration 148 902044793 The aftercooler is located behind the center access door on the operator s platform Inspect the aftercooler for debris I
28. ements Store the elements in a clean dry location Replace the primary element after the primary element has been cleaned six times Also replace the primary element if the primary element has been in service for one year 103631053 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE NOTICE Always replace the secondary filter element Never at tempt to reuse the secondary filter element by clean ing the element When the primary filter element is replaced the sec ondary filter element should be replaced The secondary filter element should also be replaced if the exhaust smoke is still black 1 Open the engine compartment 2 See Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace Remove the air cleaner cover from the air cleaner housing Remove the primary filter element from the air cleaner housing EY Illustration 189 900101451 3 Remove the secondary filter element 4 Cover the air inlet opening Clean the inside of the air cleaner housing 5 Remove the cover from the air inlet opening 6 Install the new secondary filter element 7 Install the primary filter element 8 Install the air cleaner cover and close the latches securely 9 Close the engine compartment 103790189 Engine Air Filter Service Indicator Inspect SMCS Code 7452 040 1 Start the engine 2 Run the engine at high idle KEBU7046 131 Maint
29. enance Section Engine Crankcase Breather Clean Illustration 190 902047893 3 If the yellow piston in the engine air 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 103790243 Engine Crankcase Breather Clean SMCS Code 1317 070 g02047914 Illustration 191 1 Remove the crankcase breather and the O ring seal 2 Wash the breather in clean nonflammable solvent Use pressure air in order to dry the element 3 Check the O ring seal for damage Replace the O ring seal if the O ring seal is damaged Install the O ring seal 4 Install the crankcase breather 103790333 Engine Mounts Inspect SMCS Code 1152 040 g02048014 Illustration 192 There are four engine mounts Be sure to inspect each mount Inspect the engine mounts for deterioration Inspect the engine mounts for correct bolt torque Engine vibration can be caused by improper mounting of the engine Engine vibration can be caused by loose engine mounts or deteriorated engine mounts Replace any engine mount that is deteriorated If the mounts are loose torque the fr
30. engine air inlet for any debris or obstructions Illustration 187 902047855 100058639 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY NOTICE Do not clean the filter elements by bumping or tapping them Do not use filter elements with damaged pleats gaskets or seals Engine damage can result Make sure the cleaned filter elements are completely dry before installing into the filter housing Water re maining in the elements can cause false indications of contamination in Scheduled Oil Sampling test re sults The filter elements can be cleaned by using the following methods e pressure air e pressure water e detergent washing When you use pressure air the maximum air pressure is 205 kPa 30 psi When you use pressure water the maximum water pressure is 280 kPa 40 psi 130 Maintenance Section Engine Air Filter Secondary Element Replace KEBU7046 Illustration 188 900038608 1 When you clean the inside pleats and the outside pleats direct the air along the pleats or direct the water along the pleats The element can be washed in a solution that consists of warm water and of nonsudsing household detergent Fully rinse the pleats Allow the filter to air dry completely 2 Inspect the filter elements after you clean the filter elements Do not use a filter if the pleats the gaskets or the seals are damaged 3 Cover the clean filter el
31. engine for two minutes Monitor the oil pressure gauge 11 Inspect the machine for oil leaks 12 Stop the engine 13 Wait for ten minutes in order to allow the oil to drain back into the crankcase Check the oil level 101633611 Engine Valve Lash Check SMCS Code 1105 535 This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life 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 103792710 Final Drive Planetary Oil Change SMCS Code 4050 044 OC The final drive planetary is located at the rear of the track assembly There are two final drives One final drive is on each side of the machine Perform this procedure for the final drive planetary on both sides of the machine g02049973 Illustration 198 Note The final drive planetary has three plugs Position the final drive with plug 1 at the top of the drive 1 Remove drain plug 3 and allow the oil to drain into a suitable container 2 Clean plug 3 and install the plug 3 Remove plug 1
32. es 138 Maintenance Section Fuel Tank Cap Filter and Strainer Clean Inspect Replace KEBU7046 Illustration 206 902050914 1 Open drain 2 on water separator bowl 1 2 Drain the water from water separator bowl 1 into a suitable container Close drain 2 Fuel Tank Cap Filter and Strainer Clean Inspect Replace SMCS Code 1273 070 STR 1273 070 Z2 902050935 Illustration 207 1 Remove the cap and the strainer 2 Wash the cap and the strainer in clean nonflammable solvent 3 Allow the filter inside the cap to dry or use pressure air in order to dry the filter 4 Install the strainer and the tank cap 103793710 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S g02050974 Illustration 208 1 The drain hose for the fuel tank is located in the left side access door 2 Remove the plug from the drain hose 3 Drain the water and sediment from the fuel tank into a suitable container Note Refer to Operation and Maintenance Manual General Hazard Information for information on containing fluid spillage 4 Replace the plug for the drain hose 103841549 Fuses Replace SMCS Code 1417 510 system from damage that is caused by overloaded circuits Change the fuse if the element separates If the element of the new fuse separates check the circuit Repair the problem before you operate the ma
33. f necessary clean the aftercooler Use compressed air in order to remove dust and general debris from the aftercooler Do not use water or steam in order to clean the aftercooler See Special Publication SEBD0518 Know Your Cooling System for more detailed information about cleaning radiator fins 103786216 Auger Conveyors Lubricate SMCS Code 6631 086 NOTICE All daily grease lubricant should be applied at the end of each machine operation while the machine is still warm and the asphalt is still soft or not set up Failure to do so may allow asphalt to harden around the seals and risk damaging a seal and lead to premature bear ing failure P E TAUTA D can Ej T E UH fy bea UN i E A E x D j toy Il Ha a 1 E Ss e am s ALT E Ne e amp MA WR AT Illustration 149 g02044816 Lubricate the two fittings for the outside bearings Note Add lubricant only until excess lubricant is observed at each of the bearings Lubricate the two fi
34. following procedure 1 Loosen bolts 1 2 and 3 2 Loosen nut 5 3 Tighten nut 4 until the conveyor chain has less than 6 4 mm 0 25 inch of play 4 Tighten nuts 4 and 5 until the nuts are snug 5 Tighten bolts 1 2 and 3 In order to loosen the conveyor chain use the following procedure 1 Loosen bolts 1 2 and 3 2 Loosen nut 4 until the conveyor chain has less than 6 4 mm 0 25 inch of play 3 Tighten nut 5 until the nut is snug 4 Tighten bolts 1 2 and 3 103786429 Conveyor Planetary Drive Auger Oil Change SMCS Code 5629 044 OC ev Illustration 161 902044976 Perform the following procedure on the conveyor planetary drive There is one conveyor planetary drive on each side of the machine Illustration 162 g02044977 1 Remove the drain plug 3 Allow the oil to drain into a suitable container 2 Clean the drain plug and reinstall the drain plug 3 Remove the oil filler plug 1 4 Fill the conveyor planetary through the hole for oil filler plug 1 until the oil is visible in oil level sight gauge 2 5 Clean the oil filler plug Install the oil filler plug 120 Maintenance Section Conveyor Planetary Drive Auger Oil Level Check KEBU7046 Conveyor Planetary Drive Auger O
35. ft clockwise in order to loosen the drag chain 4 Check drag chain for the correct chain tension after each adjustment 5 Place the adjusting rod in the front takeup shaft Place cotter pin 7 in adjusting rod 6 103790114 Drag Conveyors Lubricate SMCS Code 6630 086 NOTICE All daily grease lubricant should be applied at the end of each machine operation while the machine is still warm and the asphalt is still soft or not set up Failure to do so may allow asphalt to harden around the seals and risk damaging a seal and lead to premature bear ing failure KEBU7046 129 Maintenance Section Engine Air Cleaner Inlet Clean Illustration 185 902047799 Lubricate the four grease fittings on the front right side of the machine This will provide grease to the rear bearings When you use a standard grease gun pump 15 pumps per fitting The grease should purge the bearings Illustration 186 902047800 The grease points are located behind the right access door Lubricate the four grease fittings on the rear right side of the machine This will provide grease to the rear bearings When you use a standard grease gun pump 15 pumps per fitting The grease should purge the bearings 103790145 Engine Air Cleaner Inlet Clean SMCS Code 1051 070 IL The engine air inlet is located in the left side engine compartment Check the
36. il Level Check SMCS Code 5629 535 FLV Note Check the oil level of both conveyor planetary drives HL a LO t LAE i amp Ao EH o 2 O i uu E Ly Illustration 163 g02045335 1 The oil level should be visible in sight gauge 2 If necessary fill the conveyor planetary drive through the hole for oil filler plug 1 until the oil is visible in sight gauge 2 2 Clean the oil filler plug and install the oil filler plug 103786909 Conveyor Planetary Drive Auger Oil Sample Obtain SMCS Code 5629 008 7542 008 L amo i E i a t O L li Er E 1 Illustration 164 902045353 1 Remove the oil level sight gauge 2 Obtain an oil sample from the hole for the oil level sight gauge 3 Clean the oil level sight gauge Replace the oil level sight gauge Refer to Operation and Maintenance Manual SEBU6250 S O S Oil Analysis for information that pertains to obtaining a sample of oil from the conveyor planetary drive Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of oil 103786953 Conveyor Planetary Dri
37. iner 2 Remove the cap from the end of drain hose 1 Drain the oil into a suitable container Note Refer to Operation and Maintenance Manual General Hazard Information for more information on containing fluid spillage Illustration 196 902049616 3 Remove the rear access cover in order to gain access to filter 2 Remove filter 2 Discard the used filter element KEBU7046 133 Maintenance Section Engine Valve Lash Check 4 Clean the filter housing base All of the old filter seal must be removed from the filter housing base 5 Apply a thin coat of engine oil to the seal of the new filter element 6 Install the new filter by hand Instructions for the installation of the filter are printed on the side of each Caterpillar spin on filter For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter 7 Install the access cover for the oil filter g02049619 Illustration 197 8 Remove oil filler cap 3 Fill the crankcase with new oil See Operation and Maintenance Manual Capacities Refill for the correct refill capacity Clean the oil filler cap and install the oil filler cap 9 Check the engine oil level with oil level gauge 4 Maintain the oil level between the FULL mark and the ADD mark on the oil level gauge 10 Start the engine and run the
38. ker needs to be replaced 4 Press the reset button in order to reset the circuit breaker Work Tool Mode Illustration 214 902092913 You should only operate work tools from the machine s auxiliary power source when switch 3 is in the ON position Press switch 3 upward in order to turn on the work tool mode Press switch 3 downward in order to turn off the work tool mode Generator 902092253 Illustration 215 1 Press the test button 4 that is located on the circuit breaker The reset button which is located next to the test button should instantly pop out Note If the reset button does not pop out the circuit breaker needs to be replaced 2 Press the reset button in order to reset the circuit breaker 3 Repeat the above steps for all four circuit breakers that are located on the generator 103793781 Hopper Cylinder Bearings Lubricate SMCS Code 5102 086 BD Illustration 216 902051033 Left Hopper Cylinder There are two grease fittings on each hopper cylinder There is a fitting at the top of the cylinder There is a fitting at the bottom of the cylinder There are two cylinders on the machine One cylinder is on each
39. low Plug Relay Fuse 50A F Glow Plug Fuse 30A Note Spare relays are located behind the fuse panel 103857932 Generator Clean SMCS Code 4450 070 Personal injury or death can result from high volt age When power generation equipment must be in op eration to make tests and or adjustments high voltage and current are present Improper test equipment can fail and present a high voltage shock hazard to its user Make sure the testing equipment is designed for and correctly operated for high voltage and cur rent tests being made When servicing or repairing electric power gener ation equipment Make sure the unit is off line disconnected from utility and or other generators power service and either locked out or tagged DO NOT OPERATE Remove all fuses Make sure the generator engine is stopped Make sure all batteries are disconnected Make sure all capacitors are discharged Failure to do so could result in personal injury or death Make sure residual voltage in the rotor sta tor and the generator is discharged When the engine generator is operating voltages up to 600V are present in these areas near or on the regulator a the regulator terminal strip b the excitation transformer terminal strip self excited generator only NOTICE Electronic components in the regulator can be dam aged during generator operation if contact is made be tween the part and ground KEBU7
40. lt your dealer for the procedure and specifications Cleaning and Inspecting 1 Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger Visually inspect the piping for the presence of oil 2 Turn the compressor wheel and the turbine wheel by hand The assembly should turn freely Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing If there is any indication of contact between the rotating turbine wheel or the turbocharger wheel and the turbocharger housing the turbocharger should be reconditioned or replaced 3 Check the compressor wheel for cleanliness If only the blade side of the wheel is dirty dirt and or moisture is passing through the air filtering system If oil is found only on the back side of the wheel there is a possibility of a failed turbocharger oil seal The presence of oil may be the result of extended engine operation at low idle The presence of oil may also be the result of a restriction of the line for the inlet air plugged air filters which causes the turbocharger to slobber 4 Clean the turbocharger housing with standard shop solvents and a soft bristle brush 5 Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing 103862399 Ventilation Blower Wheel Inspect Clean
41. metals Ferrous metals can indicate wear on steel parts and on cast iron parts 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 may 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 103798732 Pump Drive Breather Clean SMCS Code 3108 070 BRE Illustration 225 902055053 1 Remove the breather from the gearbox 2 Wash the breather in clean nonflammable solvent 3 Allow the breather to dry or use pressure air in order to dry the breather 4 Install the breather Pump Drive Oil Change SMCS Code 3108 044 OC Illustration 226 902055056 1 Remove the cap from the drain hose 1 Allow the oil to drain into a suitable container Note Refer to Operation and Maintenance Manual General Hazard Information for information on containing fluid spillage 2 Clean the cap for the drain hose Install the cap on the drain hose
42. minated fuel will cause accelerated wear to fuel system parts 7 Ensure that the filter head is clean Push a new element fully into the filter head 8 Hold the element in place Fit the locking ring 2 into position Rotate the locking ring clockwise in order to fasten the element to the filter head Note If the nylon insert was removed install the nylon insert and install the cap 9 Prime the fuel system Refer to the Operation and Maintenance Manual Fuel System Prime in the Maintenance Section for more information Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately 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 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 204 902050876 1 Open the engine hood in
43. oil sample from the hole for the oil level sight gauge 3 Clean the oil level sight gauge Replace the oil level sight gauge Refer to Operation and Maintenance Manual SEBU6250 S O S Oil Analysis for information that pertains to obtaining a sample of oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of oil 102707486 Conveyor System Inspect SMCS Code 6630 040 6631 040 Chain Guards Illustration 168 g01358430 1 The recommended clearance between the guard and the conveyor chain is 6 35 mm 0 25 inch 2 Verify that the chain guards are not excessively worn in order to protect the chain 3 If visible wear is present and the chain is exposed the guards need to be replaced Conveyor Chain There are several methods for determining the stretch of the conveyor chain Each of these methods is listed below in reverse order of preference In order to access the conveyor chain lower the left hopper and the right hopper to the lowest positions 1 Feel for excessive motion between the bushing and the pin 122 Maintenance Section Conveyor System Inspect KEBU7046 Illustration 169 901358434 2 Inspect the amount of remaining adjustment in the chain adjustment Once most of the adjustment has been used the chain and the sprockets need to be replaced 900612551 Illustration 170 3 Measure ten pitche
44. ollow these recommenda tions could result in the damage to cooling systems components If ELC cooling system contamination occurs refer to Operation and Maintenance Extended Life Coolant ELC under the topic ELC Cooling System Contam ination J By TA E AIG DR eZ ESSm Ch 2 g02047633 oo A ENS Illustration 175 Drain the coolant whenever the coolant is dirty or whenever foaming is observed The drain valve is located on the fender above the left track inside the left access door Illustration 176 902047634 1 Open the access cover to the left of the exhaust stack 2 Slowly loosen the filler cap on the shunt tank in order to relieve the system s pressure Remove the filler cap on the shunt tank 3 Open the access door on the left side of the machine The drain hose is located on the right side of the circuit breaker box Remove the hose from the retaining clamps 4 Remove the drain plug Allow the coolant to drain into a suitable container 5 Install the drain plug 6 Fill the system with a solution which consists of clean water and of cooling system cleaner The concentration of the cooling system cleaner in the solution should be between 6 percent and 10 percent 7 Start the engine Run the engine for 90 minutes 8 Stop the engine Remove the drain plug Drain the cleaning solution into a suitable container 9 While the engine is stopped flush the system
45. on Toggle Switch Inspect 102711091 Toggle Switch Inspect SMCS Code 7332 040 Illustration 238 901360853 1 Switch in neutral position 2 Displaced switch 3 Seal Perform the following steps in order to inspect the Switches on your machine 1 Turn the engine start switch to the OFF position Do not test the switches when the machine is running 2 Visually inspect the area around the seal 3 Look for cracks or splits on the seal If any cracks or splits are noticed replace the switch 3 Lightly move the toggle switch 1 in order to test for free play If the switch moves more than 2 mm 0 01 inch in either direction replace the switch 4 Press the switch upward The toggle switch 1 should displace approximately 5 mm 0 2 inch If the switch has an incorrect displacement replace the switch Repeat the measurement when you press the switch downward 103794269 Tow Arm Joint Nuts Tighten SMCS Code 7121 079 NT There are four nuts on each tow arm i o oo o AS l CO AVG mA a AN j 902051473 Illustration 239 Torque the nuts to 373 50 N m 275 37 Ib ft There are four nuts on each side of the machine There are a total of eight nuts that need to be tightened 103794333 Tracks Inspect SMCS Code 4170 040 Illustration 240 902051535 Visually inspect the Mobil Trac System for wear or damage If there are cuts or gouges on
46. ont engine mounts and the rear engine mounts to 460 60 N m 340 x 40 Ib ft 103792150 Engine Oil Level Check SMCS Code 1000 535 FLV 1 To check the oil level stop the engine 132 Maintenance Section Engine Oil Sample Obtain KEBU7046 902049453 Illustration 193 2 Check the engine oil level with oil level gauge 2 NOTICE Do not overfill crankcase The oil level must not be above the FULL RANGE on the dipstick 3 Maintain the engine oil level on the oil level gauge between the FULL mark and the ADD mark 4 Clean oil filler cap 1 Remove the oil filler cap If necessary add oil 5 Install the oil filler cap 1 Engine Oil Sample Obtain SMCS Code 1000 008 7542 008 Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Illustration 194 902049513 Remove the rear access cover in order to gain access to oil sample port 1 Refer to Special Publication SEBU6250 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 103792283 Engine Oil and Filter Change SMCS Code 1318 510 902049615 Illustration 195 1 Remove drain hose 1 from the reta
47. or information that pertains to obtaining a sample of oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of oil 103793550 Fuel System Prime SMCS Code 1250 548 Illustration 201 902050776 1 Operate the fuel priming pump in order to fill the new filter element with fuel Push the switch downward in order to activate the fuel priming pump Hold the switch downward for a few seconds Note The fuel priming pump will only function with the engine start switch in the OFF position KEBU7046 135 Maintenance Section Fuel System Filter Washdown Clean 2 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 3 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 103797869 Fuel System Filter Washdown Clean SMCS Code 1261 070 5642 070 FI Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE
48. order to access the fuel system s secondary fuel filter 2 Remove the filter Discard the filter properly 3 Clean the mounting base of the fuel filter Remove any part of the old seal that remains on the mounting base of the fuel filter 4 Install the new filter by hand When the seal contacts the base tighten the fuel filter element by an additional 3 4 turn KEBU7046 137 Maintenance Section Fuel System Third Filter Replace Note Rotational index marks are positioned on the filter at 90 degree intervals Use these rotation index marks as a guide when you tighten the filter 5 Clean up any spills immediately 6 Start the engine and check for leaks 103799292 Fuel System Third Filter Replace SMCS Code 1261 510 1261 510 SE Personal injury or death may result from failure to adhere to the following procedures Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters NOTICE Do not fill the fuel filters with fuel before installing the fuel filters The fuel will not be filtered and could be contaminated Contaminated fuel will cause acceler ated wear to fuel system parts 1 Open the access panel on the right side of the machine Note Refer to Operation and Maintenance Manual General Ha
49. otating and moving parts Never attempt adjustments while the machine is moving or the engine is running unless otherwise specified The machine must be parked on a level surface and the engine stopped Attach a Do Not Operate or similar warning tag to the start switch and controls before servicing repairing or making adjustments to the machine E 1 m Illustration 158 1 FTTITTI r TT g00934165 To check the tension of the auger conveyor drive chain grab the auger with both hands Rotate the auger back and forth If the auger rotates more than 19 mm x 5 mm 0 75 inch the drive chain needs to be adjusted g02044945 Illustration 159 Note The adjustment procedure is used for both of the drive chains for the auger conveyor 1 Loosen four mounting bolts 1 2 Loosen jam nut 2 3 Turn adjusting nut 3 until the auger can be rotated 13 mm 0 50 inch to 19 mm 0 75 inch 4 Tighten mounting bolts 1 and jam nut 2 KEBU7046 119 Maintenance Section Conveyor Drive Chains Drag Adjust 103786530 Conveyor Drive Chains Drag Adjust SMCS Code 5620 025 CX v Q Illustration 160 902045039 In order to tighten the conveyor chain use the
50. our machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension 102429594 Seat Belt Replace SMCS Code 7327 510 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 the seat belt the seat belt buckle and the seat belt retractor 1 2 elie ioe 4 Illustration 237 g01152685 1 Date of installation retractor 2 Date of installation buckle 3 Date of manufacture tag fully extended web 4 Date of manufacture underside buckle Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware If your machine is equipped with a seat belt extension also perform this replacement procedure for the seat belt extension 100684312 Starting Motor Inspect SMCS Code 1453 040 A scheduled inspection of the starting motor is recommended If the starting motor fails the engine may not start Check the starting motor for proper operation Check the electrical connections and clean the electrical connections Refer to the Service Manual for more information on the checking procedure and for specifications or consult your dealer for assistance KEBU7046 149 Maintenance Secti
51. pair the motor 13 Inspect the ducts for the inlet side of the blower assembly Clean the ducts with nonflammable solvent 14 Reverse steps 1 through 11 in order to reassemble the ventilation system 103798138 Ventilation Inlet Ducts Inspect Clean SMCS Code 6654 040 IL 6654 070 IL e D s CIEN Y by all iN J E A Pa CI ZN na Illustration 258 902054597 The intake ducts for the ventilation system are located at the rear of the machine The ducts are above the drag conveyors There is a duct over each drag conveyor The duct is hinged Clean the ducts weekly Use nonflammable solvent in order to clean the ducts Dry the ducts before you operate the machine g02092093 Illustration 259 The manometer on the stack monitors the amount of air that is being discharged The manometer will show a minimum of 15 mm 6 inch of pressure when the ducts are clean KEBU7046 155 Maintenance Section Wheel Nuts Final Drive Tighten Note If the pressure drops below 15 mm 6 inch of pressure the ducts may need to be cleaned If the pressure drops below 15 mm 6 inch of pressure the blower may need to be cleaned i01671969 Wheel Nuts Final Drive Tighten SMCS Code 4210 527 Ls
52. radiator Compressed air is preferred but high pressure water or steam can be used to remove dust and general debris from a radiator Clean the radiator according to the condition of the radiator See Special Publication SEBD0518 Know Your Cooling System for more detailed information about cleaning radiator fins 102429589 Seat Belt Inspect SMCS Code 7327 040 7327 7520 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 Illustration 236 900932801 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 Consult your Caterpillar dealer for the replacement of the seat belt and the 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 the seat belt the seat belt buckle and the seat belt retractor If y
53. re Illustration 157 901362918 Position the machine on the incline of the slope but near the base of the slope in order to check the parking brake The test position should be 26 percent or a 15 degree slope 1 Start the engine Refer to the Operation and Maintenance Manual Engine Starting for information on starting the engine 2 Move the machine into the test position 3 Place the throttle control into the LOW IDLE position 4 Engage the parking brake The machine should not move under the following conditions e The engine is at low idle e The parking brake is applied e The machine is positioned on the specified slope 118 Maintenance Section Conveyor Drive Chains Auger Adjust KEBU7046 A WARNING Personal injury can result if the machine moves while testing If the machine begins to move release the parking brake and use the propel lever in order to move the machine to a level surface 5 Park the machine on a level surface 6 Stop the engine A WARNING If the machine moves when testing the brakes contact your Caterpillar dealer Have the dealer inspect and repair the brakes be fore returning the machine to operation Failure to have the brakes inspected and repaired can cause injury or death 103786363 Conveyor Drive Chains Auger Adjust SMCS Code 5620 025 CX A WARNING Personal injury can result from rotating and mov ing parts Stay clear of all r
54. s of chain on both strands The nominal length of a new chain is 69 85 cm 27 5 inch If the chain measures 71 95 cm 28 325 inch convenient replacement should be planned If the chain measures 72 6 cm 28 6 inch the chain needs to be replaced as Soon as possible Note When you replace the chain always replace both strands and install new sprockets Note When you follow the above guidelines also examine the chain for cracks in the links Cracked links need to be replaced Drag Bars Illustration 171 g01358441 1 New drag bars have a thickness of 31 75 mm 1 25 inch Once the bars have been worn to a thickness of 21 2 mm 0 833 inch replace the drag bars 900861324 Illustration 172 2 When you inspect the drag bars the assemblies for the roller pin should also be checked for loose pins or cracked pins If any of the pins appear worn or damaged replace the pins If any of the pins are loose replace the pins KEBU7046 123 Maintenance Section Cooling System Coolant ELC Change Auger Conveyor k d Illustration 173 900861022 The corners of new augers are square As the augers wear the thickness and diameter become smaller When the edge wears to a point the auger should be replaced Drag Pans
55. t be replaced A failure to correct a carbon tracking problem will result in an electrical short in the circuit Visually check for loose wires or broken wires Also visually check for loose connections or broken connections Check the wires and connections on the voltage regulator assembly Check all wires and connections in the generator Clean heat sinks Make any necessary repairs to the wiring Refer to Special Instruction SEHS9124 Cleaning and Drying of the Generator for more information 103846449 Ground Fault Check If Equipped SMCS Code 4450 535 4461 535 Auxiliary Power Distribution Illustration 212 902092914 902092916 Illustration 213 1 Press the test buttons 1 that are located on the outlets The reset button which is located next to the test button should instantly pop out Note If the reset button does not pop out the outlet needs to be replaced 2 Press the reset button in order to reset the outlet 142 Maintenance Section Hopper Cylinder Bearings Lubricate KEBU7046 3 Press test buttons 2 that are located on the circuit breakers The reset button which is located next to the test button should instantly pop out Note If the reset button does not pop out the circuit brea
56. the track that could affect the performance of the machine replace the damaged component immediately In order to extend the life of the track periodically rotate the belts When you rotate the belts you better distribute the wear Consult with your Caterpillar dealer before you attempt this procedure 150 Maintenance Section Track Roller Bearings Inspect KEBU7046 103794328 Track Roller Bearings Inspect SMCS Code 4180 040 BD Sy CA Illustration 241 g00863637 There are four rollers on each side of the track There are a total of eight rollers on each side of the machine There are a total of sixteen rollers that need to be checked Remove the plug on the roller Inspect the hub for the presence of oil Install the plug on the roller 103794370 Track Roller Bearings Lubricate SMCS Code 4180 086 BD Illustration 242 g01380392 There are four rollers on each side of the track There are a total of eight rollers on each side of the machine There are a total of sixteen rollers that need to be lubricated Remove the plug 1 on the roller Fill each hub with SAE 30W oil until excess oil is observed Install the plug on the roller Note The five inboard rollers may be accessed by placing the machine on supports 103797950 Track Roller Frame Lubricate SMCS Code 4151 086
57. tray under fuel filter 1 in order to catch any fuel that might spill Clean up any spilled fuel immediately 136 KEBU7046 Maintenance Section Fuel System Secondary Filter Replace 103793612 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 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 2 Clean the outside of fuel filter assembly Open the drain 4 on the bottom of the fuel filter Drain the fuel and the water from the element into a suitable container 3 Hold the element and rotate the locking ring 2 counterclockwise Remove the locking ring 2 The used filter element should be removed and discarded 4 Remove the sediment bowl 3 from the element 5 Thoroughly clean the sediment bowl 3 Inspect the O ring seals Install new O ring seals if necessary 6 Install the sediment bowl to the new element Hand tighten the sediment bowl Note Hand tightening is the only method that should be used NOTICE Do not fill fuel filters with fuel before installing them Conta
58. ttings for the inside bearings KEBU7046 115 Maintenance Section Auger Slide Adjust Auger Slide Adjust SMCS Code 6631 025 P LE 1 J y i n dici RE Es A cs en E id ye amm Li WI E ay J m H HB E p E J XKERN Id las AI a TT joa 2 2 gj Hu E dL DS _ 34 i 3 sa SA SHIT be 4M ma zd IET 902044855 Illustration 150 In order to adjust the auger slide use the following procedure 1 Loosen the four nuts 2 2 Tighten the four bolts 1 until there is firm contact for each bolt 3 Loosen each one half of a turn 4 Tighten the nuts 2 until the nuts are snug 103786280 Auger Slide Lubricate SMCS Code 6631 086 Ay i n zd IOTER TES a d j Ya u dd g ah N d m m BE m ool
59. turbocharger compressor wheel and or to the engine may occur Damage to the turbocharger compressor wheel could allow parts from the compressor wheel to enter an engine cylinder This can cause additional damage to the pistons the valves and the cylinder head NOTICE Turbocharger bearing failures can cause large quan tities of oil to enter the air inlet and exhaust systems Loss of engine lubricant can result in serious engine damage Minor leakage of a turbocharger housing under ex tended low idle operation should not cause problems as long as a turbocharger bearing failure has not oc curred When a turbocharger bearing failure is accompanied by a significant engine performance loss exhaust smoke or engine rpm up at no load do not continue engine operation until the turbocharger is repaired or replaced An inspection of the turbocharger can minimize unscheduled downtime An inspection of the turbocharger can also reduce the chance for potential damage to other engine parts Note Turbocharger components require clearances that are very precise The turbocharger cartridge must be balanced due to high rpm Severe Applications can accelerate component wear Severe Applications may suggest the need to inspect the cartridge at more frequent intervals Removal and Installation For options regarding the removal installation repair and replacement consult your dealer Refer to the Service Manual for this engine or consu
60. val In order to receive the full effect of S O S analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant Complete the information on the label for the sampling bottle before you begin to take the samples Keep the unused sampling bottles stored in plastic bags Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location 126 Maintenance Section Cooling System Coolant Sample Level 2 Obtain KEBU7046 Keep the lids on empty sampling bottles until you are ready to collect the sample e Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from expansion bottles e Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 103789998 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 7542 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using
61. ve Drag Oil Change SMCS Code 5629 044 OC Note Perform the following procedure on the two conveyor planetaries 3 Illustration 165 902045395 1 Remove the drain plug 3 Allow the oil to drain into a suitable container 2 Clean the drain plug and reinstall the drain plug 3 Remove the oil filler plug 1 4 Fill the conveyor planetary through the hole for oil filler plug 1 There are two sight gauges 2 on the conveyor planetary The oil level should be visible in the front sight gauge and the rear sight gauge should be full 5 Clean the oil filler plug Install the oil filler plug KEBU7046 121 Maintenance Section Conveyor Planetary Drive Drag Cil Level Check 103786970 Conveyor Planetary Drive Drag Oil Level Check SMCS Code 5629 535 FLV Note Check the oil level of both conveyor planetaries Illustration 166 902045433 1 There are two sight gauges 2 on the conveyor planetary The oil level should be visible in the front sight gauge and the rear sight gauge should be full If necessary fill the conveyor planetary drive through the hole for oil filler plug 1 2 Clean the oil filler plug and install the oil filler plug 103787013 Conveyor Planetary Drive Drag Oil Sample Obtain SMCS Code 5629 008 7542 008 Illustration 167 902090814 1 Remove the oil level sight gauge 2 Obtain an
62. with water Flush the system until the draining water is transparent 10 Install the drain plug Return the drain hose to the retaining clamp 11 Refill the cooling system with coolant Refer to Operation and Maintenance Manual Capacities Refill for the correct refill capacity 12 Start the engine Run the engine without the filler cap on the shunt tank until the thermostat opens and the coolant level stabilizes Illustration 177 901402853 13 Maintain the coolant level between the indicated lines 14 Replace the filler cap on the shunt tank if the gasket is damaged Install the filler cap on the shunt tank KEBU7046 125 Maintenance Section Cooling System Coolant Extender ELC Add 15 Stop the engine 16 Close and lock the access covers 101667832 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 13 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 oz 50 to 64 L 13 to 17 US g
63. ximum engine performance and maximum utilization of your engine inspect the belts for wear and for cracking Belt slippage will decrease the belt life Belt slippage will cause poor performance of the alternator or any equipment that is driven by the belt This engine is equipped with a belt tightener that automatically adjusts the belt to the correct tension KEBU7046 117 Maintenance Section Braking System Test Alternator Illustration 155 902044913 1 Turn the belt tensioner in order to release the tension from the alternator belt 1 2 Remove the belt 3 Install a new belt Generator Illustration 156 902092455 1 Turn the belt tensioner in order to release the tension from the generator s belt 2 2 Remove the belt 3 Install a new belt 102711449 Braking System Test SMCS Code 4250 081 4251 081 4267 081 Note If the machine configuration changes the parking brake needs to be tested Check the area around the machine Make sure that the machine is clear of personnel and clear of obstacles Fasten the seat belt before checking the parking brake The following tests are used in order to determine if the parking brake is functional on a specified grade or a specified slope These tests are not intended to measure the maximum brake holding effort Read all of the steps before you perform the following procedu
64. yor Planetary Drive Auger Oil Change 119 Conveyor Planetary Drive Auger Oil Sample QBA x tu iet bee ons 120 Conveyor Planetary Drive Drag Oil Change 120 Conveyor Planetary Drive Drag Oil Sample Obt iri cn Asati einai ene aes 121 Final Drive Planetary Oil Change 133 Final Drive Planetary Oil Sample Obtain 134 Tow Arm Joint Nuts Tighten ssssse 149 Wheel Nuts Final Drive Tighten 155 Every 50 Service Hours or Weekly Hopper Cylinder Bearings Lubricate 142 Track Roller Frame Lubricate 150 Every 250 Service Hours Aftercooler Core Inspect Clean 114 Auger Slide Adjust sssesess 115 Belts Inspect Adjust Replace 116 Conveyor Drive Chains Auger Adjust 118 Conveyor Drive Chains Drag Adjust 119 Conveyor Planetary Drive Auger Oil Level eire dep 120 Conveyor Planetary Drive Drag Oil Level erre d 121 Drag Conveyors Adjust ssseseessss 128 Engine Oil Sample Obtain 132 Final Drive Planetary Oil Level Check 134 Fuel System Filter Washdown Clean 135 Fuel System Primary Filter Clean Inspect Replace or e e ers tete 135 Fuel System Secondary Filter Replace 13
65. zard Information for information on containing fluid spillage 902055835 Illustration 205 2 Remove the filter Note Always discard used filters according to local regulations 3 Clean the filter mounting base Make sure that all of the used seal is removed 4 Coat the seal of the new filter with clean diesel fuel 5 Install the new fuel filter by hand Instructions for the installation of the filter are printed on the side of each Caterpillar spin on filtrer For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter 6 Prime the fuel system See Operation and Maintenance Manual Fuel System Prime for instructions 7 Close the engine hood 103793628 Fuel System Water Separator Drain SMCS Code 1263 543 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 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandat

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