MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt © 2010 Caterpillar All Rights Reserved ® ®
SEBU7858-03 July 2009 Operation and Maintenance Manual 627G Wheel Tractor-Scraper DBD1-Up (Machine) DBZ1-Up (Scraper) SAFETY.CAT.
SEBU7858-03 99 Maintenance Section Maintenance Interval Schedule i03641566 Maintenance Interval Schedule SMCS Code: 1000; 7000; 7500; 7519 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.
100 Maintenance Section Maintenance Interval Schedule SEBU7858-03 Every 500 Service Hours or 3 Months Crankshaft Vibration Damper - Inspect ............... 123 Accumulator (Cushion Hitch) - Check ................. 101 Auger Bearing Oil Level - Check ........................ 104 Auger Hydraulic System Oil Filter - Replace ...... 106 Auger Shoes and Cutting Edges - Inspect/ Replace ............................................................. 108 Brake Camshaft Bearing - Lubricate ....................
SEBU7858-03 101 Maintenance Section Accumulator (Cushion Hitch) - Check i02228281 i01778508 Accumulator (Cushion Hitch) Check Air Dryer - Check SMCS Code: 5077-535 S/N: DBD1-Up SMCS Code: 4285-535 S/N: DBD1-Up Illustration 101 g01124228 The cushion-hitch accumulator is located on the right side of the machine near the center hitch. Check the precharge pressure in the cushion-hitch accumulator. Add nitrogen, if necessary.
102 Maintenance Section Air Dryer Desiccant - Replace SEBU7858-03 4. If there is moisture in the air tank, replace air dryer desiccant cartridge (3) or rebuild air dryer desiccant cartridge (3). Consult your Caterpillar dealer for information about replacing air dryer desiccant cartridge (3) and for instructions for rebuilding air dryer desiccant cartridge (3). Note: Small amounts of moisture may be in the system due to condensation in the system.
SEBU7858-03 Illustration 106 103 Maintenance Section Auger Bearing Oil - Change g00909637 Illustration 107 g00943824 The air tank for the scraper is on the right rear side of the scraper. Note: The bearing is located on the lower end of the auger. Open drain valve (2). Allow the moisture and the sediment to drain into a suitable container. Close valve (2). 5. Clean the area around screws (1) and cover (2). 6. Remove screws (1) and cover (2).
104 Maintenance Section Auger Bearing Oil Level - Check SEBU7858-03 6. Remove screws (1) and cover (2). 13. Install cover (2) and screws (1). i02457745 Auger Bearing Oil Level Check SMCS Code: 6282-535-BD S/N: DBZ1-Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product.
SEBU7858-03 105 Maintenance Section Auger Drive Gear Oil - Change 3. Lower the bowl to the ground. Open the apron. Lock the apron in the RAISED position. Refer to Operation and Maintenance Manual, “Blocking the Bowl and Apron” for further information. 4. Stop the engine. Illustration 111 g00944004 Note: Breather (1) is located on the gearbox for the auger. Do not operate the machine without the breather. 5. Clean the area around the breather. Illustration 112 6. Remove the breather.
6 Maintenance Section Auger Drive Gear Oil Level - Check SEBU7858-03 i02457759 i02457762 Auger Drive Gear Oil Level Check Auger Hydraulic System Oil Filter - Replace SMCS Code: 5326-535-FLV SMCS Code: 5068-510-AG S/N: DBZ1-Up S/N: DBD1-Up Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. Illustration 113 g00944009 Sight gauge (2) is located on the left side of the auger gearbox. 1. Park the machine on level ground.
SEBU7858-03 107 Maintenance Section Auger Seal - Inspect/Replace 8. Tighten the filters according to the instructions that are printed on the filters. Use the index marks as a guide for tightening the filters. For non-Caterpillar filters, refer to the installation instructions that are provided by the supplier of the filters. Note: You may need to use a Caterpillar strap wrench, or another suitable tool, in order to turn the filters to the amount that is required for final installation.
108 Maintenance Section Auger Shoes and Cutting Edges - Inspect/Replace Note: Consult your Caterpillar dealer for further information on replacement of the seal. i02558606 Auger Shoes and Cutting Edges - Inspect/Replace SMCS Code: 6282-040-QH; 6282-510-QH; 6801-040; 6801-510 SEBU7858-03 Wear Shoes (1) The wear shoes that are located on the lower one half of the auger will wear faster than the wear shoes that are located on the upper one half of the auger.
SEBU7858-03 109 Maintenance Section Bail Bearings and Push Plate Spring - Lubricate The backup alarm should sound immediately. The alarm alerts the personnel behind the machine that the machine is backing up. The backup alarm should continue to sound until the transmission control lever is moved to the NEUTRAL position or to the FORWARD position. i01779494 Bail Bearings and Push Plate Spring - Lubricate SMCS Code: 6262-086; 7115-086-BD 3.
110 Maintenance Section Belts - Inspect/Replace SEBU7858-03 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. • missing pieces • frayed areas 4. Close the engine access cover. 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.
SEBU7858-03 111 Maintenance Section Bowl Lift Cylinder Bearings - Lubricate Replace i02443636 If the belts need replacement, refer to the Service Manual or contact your local Caterpillar dealer. i02556173 Brake Air System Pressure Test SMCS Code: 4250-081-PX Bowl Lift Cylinder Bearings Lubricate SMCS Code: 5303-086-BD S/N: DBZ1-Up Illustration 121 g01128849 Illustration 122 g01220965 The fittings for the bowl lift cylinder bearings are located on the front of the bowl. 1.
112 Maintenance Section Brake Camshaft Bearing - Lubricate SEBU7858-03 3. Start the engine. 1. Remove the covers that are on the fittings. 4. Watch the air pressure gauge. The air pressure must be above 517 ± 35 kPa (75 ± 5 psi). 2. Wipe the fittings before you apply lubricant through the fittings. 5. Purge air from the air tanks by doing the following procedure: 3.
SEBU7858-03 113 Maintenance Section Brakes, Indicators and Gauges - Test i02444593 Brakes, Indicators and Gauges - Test This test determines whether the service brake is functional. This test is not intended to measure the maximum brake holding effort. 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: 1.
114 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 conditioning for maximum performance. Consult your Caterpillar dealer or see Special Instruction, SEHS9187 for the procedure for conditioning. Parking Brake Holding Ability Test Make sure that no people or obstacles are in the area around the machine. Test the brakes on a dry, level surface.
SEBU7858-03 115 Maintenance Section Circuit Breakers - Reset 3. After you clean the filter element, inspect the filter element. Do not use a filter element with damaged pleats or a damaged seal. If the filter element is damaged, replace the filter element. 4. Install the filter element. Reinstall access cover (5). Replace latches (4). i02558339 Circuit Breakers - Reset SMCS Code: 1420-529 Illustration 128 g01166347 Circuit Breakers (Tractor) 2.
116 Maintenance Section Condenser (Refrigerant) - Clean SEBU7858-03 Circuit Breaker Panel 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.
SEBU7858-03 117 Maintenance Section Cooling System Coolant (ELC) - Change 1. Remove the radiator grill. 2. Inspect the condenser for debris. If necessary, clean the condenser. 3. Use clean water in order to wash off all dust and dirt from the condenser. 4. Replace the radiator grill. i02556719 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.
118 Maintenance Section Cooling System Coolant (ELC) - Change SEBU7858-03 Procedure for the Scraper Illustration 134 g01121792 4. The coolant drain valve is located behind guard (2). Remove access cover (1) for the coolant drain valve. 5. Open the coolant drain valve. Drain the coolant into a suitable container. Illustration 135 6. Flush the cooling system with clean water until the draining water is transparent. 7. Close the coolant drain valve. Install the access cover. 8. Add ELC.
SEBU7858-03 119 Maintenance Section Cooling System Coolant Extender (ELC) - Add 9. Check the coolant level. The radiator is full when the sight gauge is completely covered. Also, the radiator is full when the coolant level reaches the top of the angled cut on the filler tube. Refer to Operation and Maintenance Manual, “Cooling System Coolant Level - Check”. Table 11 Amount of Caterpillar Extender (ELC) Cooling System Capacity Recommended Amount of Caterpillar Extender 22 to 30 L (6 to 8 US gal) 0.
120 Maintenance Section Cooling System Coolant Sample (Level 1) - Obtain SEBU7858-03 i02223947 Cooling System Coolant Sample (Level 1) - Obtain SMCS Code: 1350-008 Note: It is not necessary to obtain a Coolant Sample (Level 1) if the cooling system is filled with Cat ELC (Extended Life Coolant). Cooling systems that are filled with Cat ELC should have a Coolant Sample (Level 2) that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule.
SEBU7858-03 121 Maintenance Section Cooling System Coolant Sample (Level 2) - Obtain • Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination. • Never collect samples from expansion bottles. • Never collect samples from the drain for a system. Submit the sample for Level 1 analysis. For additional information about coolant analysis, see Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations” or consult your Caterpillar dealer.
122 Maintenance Section Cooling System Pressure Cap - Clean/Replace i02224339 Cooling System Pressure Cap - Clean/Replace SMCS Code: 1382-070; 1382-510 The cooling system pressure cap for the tractor is located on the top of the tractor underneath the hood cover. The pressure cap is directly above the radiator. SEBU7858-03 5. Install the pressure cap. i02558927 Cooling System Water Temperature Regulator Replace SMCS Code: 1355-510 Personal injury can result from hot coolant, steam and alkali.
SEBU7858-03 3. Remove the turbocharger water line from the cover assembly. 4. Clean the area around the water temperature regulator housing. 5. Remove the bolts from the water temperature regulator housing and remove the water temperature regulator housing. 6. Remove the water temperature regulator from the water temperature regulator housing. Remove the gasket from the water temperature regulator housing. Remove the seal from the water temperature regulator housing.
124 Maintenance Section Cutting Edges and End Bits - Inspect/Replace SEBU7858-03 i02216604 Cutting Edges and End Bits Inspect/Replace SMCS Code: 6801-040; 6801-510; 6804-040; 6804-510 S/N: DBZ1-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.
SEBU7858-03 125 Maintenance Section Differential Thrust Pin Clearance - Check i02444371 Differential Thrust Pin Clearance - Check SMCS Code: 3258-535-T9 S/N: DBD1-Up Illustration 146 g00919964 The differential and final drive breather for the scraper is located on the fuel tank above the top of the transmission oil reservoir. The transmission oil reservoir is on the left side of the scraper engine. Use the following procedure to clean the breathers. Illustration 144 g00919942 1. Remove the breather.
126 Maintenance Section Differential and Final Drive Oil - Change SEBU7858-03 Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. Note: Drain plug (3) is located on the hub of the wheel. Drain plug (3) must be at the lowest point in order to drain the final drive. 5. Clean the area around drain plug (3). 6. Remove drain plug (3). Drain the oil into a suitable container. Procedure for the Tractor 7. Clean drain plug (3). Install drain plug (3).
SEBU7858-03 127 Maintenance Section Differential and Final Drive Oil - Change Procedure for the Scraper 7. Clean plug (8). Install plug (8). The differential housing is located under the transmission of the scraper. 8. Repeat this procedure for the other wheel. Note: Move the ejector forward in order to make access to the differential housing easier. Illustration 152 Illustration 150 g00920325 Operate the machine until the differential oil is warm. Park the machine on a level surface.
128 Maintenance Section Differential and Final Drive Oil Level - Check SEBU7858-03 i01797397 Differential and Final Drive Oil Level - Check Oil filler tube (3) for the differential of the scraper is located on the right side of the scraper engine. 1. Park the machine on level ground. SMCS Code: 3258-535-FLV; 4050-535-FLV 2. Lower the bowl. Shut off the engine. Procedure for the Tractor 3. Clean the cap. Remove the cap. Remove the dipstick which is under the cap. 4.
SEBU7858-03 129 Maintenance Section Draft Arm Wear Plates - Check/Adjust A sample of the differential and the final drive oil can be obtained by pulling a sample through the filler tube. Filler tube (1) is located on the right side of the scraper engine. Filler tube (2) is located on the rear right side of the tractor transmission. 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.
130 Maintenance Section Ejector Carrier Rollers - Inspect/Pack/Replace 6. Repeat Step 3 through Step 5 in order to adjust the other ejector carrier roller. SEBU7858-03 i02501049 7. Start the engine. Ejector Guide Rollers Check/Adjust 8. Move the ejector forward and backward. SMCS Code: 6230-025; 6230-535 9. Stop the engine. S/N: DBZ1-Up 10. Check for drag between the ejector and the bottom of the bowl. Repeat the adjustment procedure, if necessary.
SEBU7858-03 131 Maintenance Section Ejector Guide Rollers - Inspect/Pack/Replace 11. Check for drag between the ejector guide rollers and the sides of the bowl. Repeat the adjustment procedure, if necessary.
132 Maintenance Section Ejector Support Rollers - Inspect/Pack/Replace SEBU7858-03 i02501093 i01798044 Ejector Support Rollers Inspect/Pack/Replace Electronic Unit Injector Inspect/Adjust SMCS Code: 6230-040; 6230-086; 6230-510 SMCS Code: 1251-025; 1251-040; 1290-025; 1290-040 S/N: DBZ1-Up Be sure the engine cannot be started while this maintenance is being performed. To prevent possible injury, do not use the starting motor to turn the flywheel. Hot engine components can cause burns.
SEBU7858-03 133 Maintenance Section Engine Air Filter Primary Element - Clean/Replace 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”. Cleaning Primary Air Filter Elements NOTICE Caterpillar recommends certified air filter cleaning services available at participating Caterpillar dealers.
134 Maintenance Section Engine Air Filter Primary Element - Clean/Replace 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).
SEBU7858-03 135 Maintenance Section Engine Air Filter Secondary Element - Replace Do not use paint, a waterproof cover, or plastic as a protective covering for storage. An air flow restriction may result. To protect against dirt and damage, wrap the primary air filter elements in Volatile Corrosion Inhibited (VCI) paper. 4. Uncover the air inlet opening. Install a new secondary element. Place the primary air filter element into a box for storage.
136 Maintenance Section Engine Air Filter Service Indicator - Inspect/Replace 1. Use a towel to remove the dust which has collected on the indicator (1). 2. Examine the indicator. The machine may be operated when the indicator is yellow. The machine should not be operated when the indicator is red. If the indicator is red, the air filter will need to be cleaned or the air filter will need to be replaced. 3. Once the air filter has been checked, the indicator should be reset.
SEBU7858-03 137 Maintenance Section Engine Oil (High Speed) and Oil Filter - Change i02324351 Engine Oil (High Speed) and Oil Filter - Change SMCS Code: 1318-510-HZ 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, testing, adjusting and repair of the product.
138 Maintenance Section Engine Oil (High Speed) and Oil Filter - Change Note: There are rotation index marks on the engine oil filter that are spaced 90 degrees or 1/4 of a turn away from each other. When you tighten the engine oil filter, use the rotation index marks as a guide. 8. Tighten the oil filter according to the instructions that are printed on the filter. Use the index marks as a guide for tightening the oil filter. SEBU7858-03 2.
SEBU7858-03 139 Maintenance Section Engine Oil Level - Check • Operation and Maintenance Manual, “Capacities 1. Park the machine on level ground. Lower the bowl. • Operation and Maintenance Manual, “Engine 2. Open the engine access cover that is on the right side of the machine. (Refill)” Oil Level - Check” 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.
140 Maintenance Section Engine Oil Sample - Obtain SEBU7858-03 The dipstick (4) for the scraper engine is located on the right side of the scraper. 1. Park the machine on level ground. Lower the bowl to the ground. 2. Remove the padlock from the dipstick (if equipped). Check the “ENGINE LOW IDLE” side of the dipstick while the engine is running. Maintain the oil level between the “ADD” mark and the “FULL” mark. Check the “ENGINE STOPPED” side of the dipstick while the engine is stopped.
SEBU7858-03 141 Maintenance Section Engine Oil and Filter - Change 2. Remove crankcase drain valve access cover (1) from guard (2). Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. Note: API CH-4, API CI-4, and API CI-4 PLUS oils are acceptable in the C15 Acert Diesel Engine if the requirements of Caterpillar's ECF-1 (Engine Crankcase Fluid specification - 1) are met. The oil change interval should not exceed 500 hours. 3.
142 Maintenance Section Engine Oil and Filter - Change SEBU7858-03 12. Clean the area around oil filler cap (5). Remove the oil filler cap . Fill the crankcase with new oil. See the following topics: • Operation and Maintenance Manual, “Lubricant Viscosities” Note: API CH-4, API CI-4, and API CI-4 PLUS oils are acceptable in the C9 Acert Diesel Engine if the requirements of Caterpillar's ECF-1 (Engine Crankcase Fluid specification - 1) are met. The oil change interval should not exceed 250 hours.
SEBU7858-03 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. Park the machine on a level surface and engage the parking brake. Stop the engine. 2. Remove crankcase drain plug (1). 3.
144 Maintenance Section Ether Starting Aid Cylinder - Replace SEBU7858-03 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. Note: In order to check the valve lash on the tractor engine, use the right hand timing calibration port. 2. Remove used gasket (2). Install the new gasket. A new gasket is provided with each new ether cylinder. 3. Install the new ether cylinder.
SEBU7858-03 145 Maintenance Section Fuel System - Prime Note: If you are operating the machine under harsh conditions or with the cab door open, it may be necessary to clean the coils more often. i02225246 Fuel System - Prime Switch (1) is located on the right side of the tractor. The fuel priming pump is on the right side of the engine compartment underneath the hood. Switch (2) is located on the right side of the scraper.
146 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace 2. Push the switch to the ON position in order to pump the fuel. SEBU7858-03 Procedure for the Tractor 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. 3. Continue to prime the fuel system until the flow of fuel is free of air bubbles. Fuel should flow continuously from the drain hose. 4.
SEBU7858-03 147 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace 9. Lubricate the O-ring with clean diesel fuel or lubricate the O-ring with clean motor oil. Place the O-ring in the groove on the water separator bowl. 10. Install water separator bowl (3) onto the new fuel filter (2) by hand. The primary fuel filter for the scraper is mounted on the left side of the scraper engine. 1. Park the machine on a level surface. 2. Lower the bowl. 11.
148 Maintenance Section Fuel System Secondary Filter - Replace SEBU7858-03 15. Purge the air from the fuel system. See the Operation and Maintenance Manual, “Fuel System - Prime” for further instructions. Note: The secondary fuel filter should also be changed at this time. See the Operation and Maintenance Manual, “Fuel System Secondary Filter - Replace” for further instructions. 16. Start the engine and check for leaks.
SEBU7858-03 149 Maintenance Section Fuel System Water Separator - Drain Procedure for the Scraper 9. Install the new fuel filter hand tight until the seal of the fuel filter contacts the filter mounting base. Note the position of the index marks on the filter in relation to a fixed point on the filter mounting base. Note: There are rotation index marks on the filter that are spaced 90 degrees or 1/4 of a turn away from each other. When you tighten the filter, use the rotation index marks as a guide. 10.
150 Maintenance Section Fuel Tank Cap and Strainer - Clean SEBU7858-03 4. Disassemble the fuel tank cap. Remove the filter elements. Clean the filter elements in clean, nonflammable solvent. 5. Apply a thin coat of oil to the filter elements. Assemble the fuel tank cap. 6. Install the gasket. 7. Remove the strainer. Clean the strainer in clean, nonflammable solvent. 8. Install the strainer. Illustration 201 g01158078 9. Clean the fuel tank cap. Install the fuel tank cap.
SEBU7858-03 151 Maintenance Section Fuses - Replace The drain valve for the fuel system is located behind the right scraper wheel. The drain valve is located inside the rear frame. This drain valve is used for draining diesel fuel from the fuel tank. 1. Move the drain valve to the OPEN position. 2. Collect the fuel in a clear container that is suitable. 3. Move the drain valve to the CLOSED position in order to examine the fuel that is collected.
152 Maintenance Section Hitch - Inspect SEBU7858-03 Ether Starting Aid (8) – 10 AMP Vertical Seat Adjustment (9) – 15 AMP Caterpillar Monitoring System (10) – 15 AMP Converter (11) – 10 AMP Illustration 205 g00692116 Inspect the upper hitch pin (1) for wear. Inspect the lower hitch pin (2) for wear. Replace the pins if it is necessary.
SEBU7858-03 153 Maintenance Section Hitch - Lubricate There are six pins (4), (5), (6), (7), (8) and (9) in the links for the steering. Inspect the pins for wear or for damage. Replace the pins in the links for the steering if it is necessary. Hydraulic Oil Cooler - Clean Note: Refer to the Disassembly and Assembly for further information.
154 Maintenance Section Hydraulic System Oil - Change SEBU7858-03 Note: The normal hydraulic oil change interval is at every 2000 Service Hours or 1 Year. By performing S·O·S oil analysis, the hydraulic oil change interval may be extended to 4000 Service Hours or 2 Years. S·O·S oil analysis must be performed at every 500 Service Hours or 3 Months in order to extend the hydraulic oil change interval.
SEBU7858-03 155 Maintenance Section Hydraulic System Oil Filter (Pilot) - Replace 12. Fill the hydraulic tank to the proper level. Refer to the following topics: • Operation and Maintenance Manual, “Lubricant Viscosities” • Operation and Maintenance Manual, “Capacities (Refill)” • Operation and Maintenance Manual, “Hydraulic System Oil Level - Check” 13. Inspect the cap seal for damage. If the seal is damaged, replace the seal.
156 Maintenance Section Hydraulic System Oil Filter - Replace SEBU7858-03 Note: There are rotation index marks on the filter that are spaced 90 degrees or 1/4 of a turn away from each other. When you tighten the filter, use the rotation index marks as a guide. 8. Tighten the filter according to the instructions that are printed on the filter. Use the index marks as a guide for tightening the filter.
SEBU7858-03 157 Maintenance Section Hydraulic System Oil Level - Check i02503111 Hydraulic System Oil Level Check SMCS Code: 5050-535-FLV S/N: DBD1-Up Note: Before you check the hydraulic tank oil level, the machine must meet the following conditions: • The machine must be level. • The parking brake must be applied. Illustration 215 • The hydraulic oil must be warm. g01124666 2. If necessary, add oil to the hydraulic tank. • The engine must be running at low idle.
158 Maintenance Section Hydraulic Tank Breaker Relief Valve - Clean SEBU7858-03 Type 1 i02503169 Hydraulic Tank Breaker Relief Valve - Clean SMCS Code: 5118-070 S/N: DBD1-Up Illustration 216 g01124705 The hydraulic oil sampling valve is located on top of the return tube near the hydraulic tank. Type 2 Illustration 218 g01124743 The hydraulic tank breaker relief valve is located on the top of the hydraulic tank near the hydraulic oil filler cap.
SEBU7858-03 159 Maintenance Section Oil Filter - Inspect 10. Apply a thin film of clean hydraulic oil to the O-ring. Assemble the filter on the breaker relief valve. 11. Install the breaker relief valve on the hydraulic tank. 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.
160 Maintenance Section Refrigerant Dryer - Replace SEBU7858-03 i02318448 Refrigerant Dryer - Replace SMCS Code: 7322-710 S/N: DBD1-Up Personal injury can result from contact with refrigerant. Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury. Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant. Always use precaution when a fitting is removed. Slowly loosen the fitting.
SEBU7858-03 161 Maintenance Section Seat Belt - Inspect i02429589 i02429594 Seat Belt - Inspect Seat Belt - Replace SMCS Code: 7327-040 SMCS Code: 7327-510 S/N: DBD1-Up S/N: DBD1-Up 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.
162 Maintenance Section Steering Pump Outlet Screen - Clean Illustration 224 SEBU7858-03 g00100829 2. Route the pressure gauge to a location that allows the operator to see the gauge and safely drive the machine. Illustration 226 g00922722 The steering pump outlet screen is located inside the left frame rail of the tractor. 3. Start the engine. Operate the machine at approximately 16 km/h (10 mph).
SEBU7858-03 163 Maintenance Section Suction Screen (Transmission Scavenge) - Clean Procedure for the Tractor 16. Stop the engine. Procedure for the Scraper Illustration 227 g00927795 The suction screen for the transmission is located at the left rear of the transmission for the tractor. Illustration 228 1. Park the machine on level ground. Engage the parking brake. The suction screen is located below the transmission for the scraper. 2. Lower the bowl to the ground. Shut off the engine.
164 Maintenance Section Tire Inflation - Check SEBU7858-03 13. Check the transmission oil level. Add oil, if necessary. Refer to Operation and Maintenance Manual, “Transmission Oil Level - Check” for the proper procedure. 1. Park the machine on level ground. Apply the parking brake. 14. Stop the engines. 3. Clean the area around the valve stem for the tire. i02449833 Tire Inflation - Check 2. Lower the bowl to the ground. Shut off the engine. 4. Remove valve stem cap (1). 5.
SEBU7858-03 165 Maintenance Section Transmission Oil - Change Procedure for the Tractor Illustration 231 g00923132 The transmission breather for the scraper is located on the top of the transmission oil reservoir at the left rear of the scraper. Use the following procedure to clean each breather. 1. Clean the area around the breather. Illustration 232 g01279936 (1) Differential drain plug (2) Transmission drain plug Transmission drain plug (2) is located under the tractor.
166 Maintenance Section Transmission Oil - Change 6. Clean the area around oil filler cap (3). Remove the oil filler cap. Fill the transmission with oil through the filler tube to the “FULL” mark in sight gauge (4). Refer to Operation and Maintenance Manual, “Capacities (Refill)” and Operation and Maintenance Manual, “Lubricant Viscosities” for additional information. SEBU7858-03 Procedure for the Scraper Note: Red dye is added to the transmission oil at the factory.
SEBU7858-03 167 Maintenance Section Transmission Oil Filter and Magnetic Screen - Replace/Clean 5. Housing (10) for the suction screen is located below the transmission on the left side of the scraper engine. Clean the area around housing (10) for the suction screen. 6. Remove line (9) from housing (10). Drain the oil into a suitable container. 7. Install the line. Note: Clean the suction screen at this time.
168 Maintenance Section Transmission Oil Filter and Magnetic Screen - Replace/Clean SEBU7858-03 7. Clean the inside of the transmission oil filter housing with a clean towel. 8. Clean the magnets with a towel or clean the magnets with a stiff bristle brush. 8. Insert a new filter element into the transmission oil filter housing. 9. Install the magnets into the magnetic screen. 9. Inspect the seal for the transmission oil filter housing. Replace the seal if the seal is damaged. 10.
SEBU7858-03 169 Maintenance Section Transmission Oil Filter and Magnetic Screen - Replace/Clean Procedure for the Scraper 5. Remove bolts (7) from the transmission oil filter housing. Remove the cover from the transmission oil filter housing. 6. Remove the used filter element and discard the used filter element according to local regulations. 7. Clean the inside of the transmission oil filter housing with a clean towel. 8. Insert a new filter element into the transmission oil filter housing. 9.
170 Maintenance Section Transmission Oil Level - Check SEBU7858-03 13. Check the transmission oil filter for leaks. Check the magnetic screen for leaks. 14. Check the oil level of the transmission. Add oil, if necessary. 15. Stop the engine. i02558899 Transmission Oil Level - Check Note: Red dye is added to the transmission oil at the factory. If the oil in differential oil level sight gauge (3) has a red color, transmission oil has leaked into the differential.
SEBU7858-03 171 Maintenance Section Transmission Oil Sample - Obtain i02319444 Transmission Oil Sample Obtain i02446418 Wheel Coolant Level - Check SMCS Code: 4207-535-FLV SMCS Code: 3030-008; 7542-008 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 produces gases inside the tire that can explode, endangering personnel within 500 meters (1500 feet).
172 Maintenance Section Window Washer Reservoir - Fill SEBU7858-03 6. Perform Step 1 through Step 5 for the other wheels. i02210505 Window Washer Reservoir Fill i01774940 Window Wiper Inspect/Replace SMCS Code: 7305-040; 7305-510 S/N: DBD1-Up SMCS Code: 7306-544 S/N: DBD1-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.
SEBU7858-03 Illustration 245 173 Maintenance Section Windows - Clean g01421075 Clean the left side windows of the cab while you are standing on the ground or on a stable work platform. Use the appropriate equipment in order to reach the left side windows. If you are standing on the ground, use a squeegee with an extension handle. Clean the front, right side, and rear windows from the top of the engine enclosure.
