Caterpillar 257 - General Maintenance

Battery - Recycle

• Always recycle a battery. Never discard a battery.

• Always return used batteries to one of the following locations:

• • A battery supplier

• • An authorized battery collection facility

• • Recycling facility

Battery or Battery Cable - Inspect/Replace

• Turn the engine start switch to the OFF position. Turn all switches to the OFF position.

• Disconnect the negative battery cable from the starter.

• Note: Do not allow the disconnected battery cable to contact the frame of the machine.

• Disconnect the negative battery cable at the battery.

• Perform the necessary repairs. Replace the cable or the battery, as needed.

• Connect the negative battery cable at the battery.

• Connect the battery cable to the starter of the machine.

• Install the engine start switch key.

• Repeat the process for the positive battery cable.

Bucket Cutting Edges - Inspect/Replace

• Lower the lift arms fully. Tilt back the bucket so that the bucket cutting edge is accessible.

• Place blocks under the raised edge of the bucket.

• Remove the bolts. Remove the cutting edge and the end bits.

• Clean the contact surfaces.

• Use the opposite side of the cutting edge, if this side is not worn.

• Install a new cutting edge, if both edges are worn.

• Install the bolts.

• Remove the blocks that are under the bucket.

• After a few hours of operation, check the bolts for proper torque.

Bucket Tips - Inspect/Replace

• Lower the lift arms fully. Tilt back the bucket so that the bucket tips are accessible.

• Place blocks under the raised edge of the bucket.

• Remove the mounting bolts. Remove the bucket tips.

• Clean the mounting surface.

• Replace the bucket tips.

• Install the bolts.

• Remove the blocks that are under the bucket

• After a few hours of operation, check the bolts for proper torque.

Cab Air Filter - Clean/Replace

• Raise the loader lift arms. Install the brace for the loader lift arm. Refer to Operation and Maintenance Manual, “Loader Lift Arm Brace Operation”.

• Remove the filter cover.

• Remove the seal from the cover and inspect the seal. If the seal is damaged replace the seal.

• Remove the air filter element from the cover and clean the filter element with low pressure air. Replace the element if the element is damaged.

• Install the seal onto the filter cover and install the filter element.

• Install the filter cover on the machine.

• Remove the brace for the loader lift arms and return the brace to the stored position. Refer to Operation and Maintenance Manual, “Loader Lift Arm Brace Operation”.

Circuit Breakers and Fuses - Reset/Replace

• If the element of a new fuse separates, check the circuit. Repair the circuit, if necessary

• Replace the fuses with the same type and size only. Otherwise, electrical damage can result.

• If it is necessary to replace fuses frequently, an electrical problem may exist. Contact your Caterpillar dealer

• The main circuit breaker is located in the engine compartment on the left side.

Engine Air Filter Primary Element - Clean/Replace

• Remove the air cleaner housing cover (1)

• Remove the primary filter element (2).

• Install a clean filter element and install the cover.

• Reset the engine air filter service indicator.

Engine Air Filter Secondary Element - Replace

• Remove the air cleaner housing cover (1).

• Remove the primary filter element (2).

• Remove the secondary filter element.

• Cover the air inlet opening. Clean the inside of the air cleaner housing.

• Inspect the gasket between the air inlet pipe and the air cleaner housing. Replace the gasket if the gasket is damaged.

• Uncover the air inlet opening. Install a new secondary element.

• Install the primary element and the air cleaner housing cover.

• Reset the engine air filter service indicator. Refer to Operation and Maintenance Manual, “Engine Air Filter Service Indicator - Inspect”.

Engine Compartment - Clean

• Open the engine access door. Refer to Operation and Maintenance Manual, “Access Doors and Covers”.

• Remove any debris or dirt from the engine compartment.

• Use care when you clean the engine compartment. Damage to the machine may occur.

• Close the engine access door.

Engine Starting with Jump Start Cables

• Determine the reason that the engine will not crank. The Caterpillar Electronic Technician (ET) can be used to aid in troubleshooting if the machine is equipped with the auxiliary hydraulic control module.

• Engage the parking brake. Lower the work tools to the ground. Refer to Operation and Maintenance Manual, “Equipment Lowering with Engine Stopped”. Move all control levers to the HOLD or NEUTRAL position.

• Turn the engine start switch to the OFF position and turn all accessory switches to the OFF position.

• Move the machine that is being used as an electrical source near the stalled machine so that the jump start cables reach the stalled machine. Do not allow the machines to contact each other.

• Stop the engine of the machine that is being used as an electrical source. If you are using an auxiliary power source, turn off the charging system.

• Ensure that battery caps on both machines are tight and correctly placed. Ensure that batteries in the stalled machine are not frozen.

• Connect the positive jump start cable to the positive cable terminal of the discharged battery.

• Do not allow the positive cable clamps to contact any metal except for the battery terminals.

• Connect the other positive end of the jump start cable to the positive cable terminal of the electrical source.

• Connect one negative end of the jump start cable to the negative cable terminal of the electrical source.

Engine Starting with Jump Start Cables

• Determine the reason that the engine will not crank. The Caterpillar Electronic Technician (ET) can be used to aid in troubleshooting if the machine is equipped with the auxiliary hydraulic control module.

• Engage the parking brake. Lower the work tools to the ground. Refer to Operation and Maintenance Manual, “Equipment Lowering with Engine Stopped”. Move all control levers to the HOLD or NEUTRAL position.

• Turn the engine start switch to the OFF position and turn all accessory switches to the OFF position.

• Move the machine that is being used as an electrical source near the stalled machine so that the jump start cables reach the stalled machine. Do not allow the machines to contact each other.

• Stop the engine of the machine that is being used as an electrical source. If you are using an auxiliary power source, turn off the charging system.

• Ensure that battery caps on both machines are tight and correctly placed. Ensure that batteries in the stalled machine are not frozen.

• Connect the positive jump start cable to the positive cable terminal of the discharged battery.

• Do not allow the positive cable clamps to contact any metal except for the battery terminals.

• Connect the other positive end of the jump start cable to the positive cable terminal of the electrical source.

• Connect one negative end of the jump start cable to the negative cable terminal of the electrical source.

• Connect the other negative end of the jump start cable to the engine block or to the frame of the stalled machine. Do not connect the jump start cable to the battery post. Do not allow the jump start cables to contact the battery cables, the fuel lines, the hydraulic lines, or any moving parts.

• Start the engine of the machine that is being used as an electrical source or energize the charging system on the auxiliary power source.

• Wait at least two minutes before you attempt to start the stalled machine. This will allow the battery in the stalled machine to partially charge.

• Attempt to start the stalled engine. See Operation and Maintenance Manual, “Starting the Engine” for the correct starting procedure.

• After the stalled engine starts, disconnect the negative jump start cable from the stalled machine.

• Disconnect the negative jump start cable from the negative terminal of the electrical source.

• Disconnect the positive jump start cable from the positive terminal of the electrical source.

• Disconnect the positive jump start cable from the positive terminal of the stalled machine.

• Conclude the failure analysis on the starting system of the stalled machine and/or on the charging system of the stalled machine. Check the machine while the engine is running and the charging system is in operation.

Fuel System Priming Pump - Operate

• Open the engine access door. Refer to Operation and Maintenance Manual, “Access Doors and Covers”.

• Push down on the top of the fuel priming pump plunger and release the fuel priming pump plunger in order to operate the fuel priming pump. Operate the fuel priming pump plunger in order to fill the new filter element with fuel. Continue to pump until increased resistance is felt. This resistance will indicate that the filter element is full of fuel.

• Start the engine. If the engine does 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.

• 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

• Close the engine access door.

Fuel Tank Cap - Clean

• Remove the fuel cap

• Inspect the cap. Replace the cap if the cap is damaged.

• Wash the fuel cap in a clean, nonflammable solvent and dry the fuel cap.

• Put a light coating of fuel on the cap gasket.

• Install the fuel cap.

Fuel Tank Water and Sediment - Drain

• Drain the water and the sediment from the fuel tank when the tank is almost empty.

• Slowly remove the fuel tank cap in order to relieve the tank pressure.

• The fuel tank drain plug for the 267, 277 and 287 machines is located on the side of the tank. Remove the access panel in the bottom of the machine in order to access the drain plug. Loosen the drain plug. The fuel tank drain plug for the 247 and 257 machines is located underneath the machine at the left rear corner. Loosen the plug.

• Allow the water and the sediment to drain into a suitable container.

• Install the fuel tank drain plug.

• Apply 5P-3413 Pipe Sealant to the threads on the drain plug.

• Install the fuel tank cap.

Lower Machine Frame - Clean

• Tilt the cab upward. Refer to Operation and Maintenance Manual, “Cab Tilting”.

• Remove the access panel in the frame that is located underneath the machine.

• Remove any debris or dirt from the inside of the frame.

• Reinstall the access panel and tilt the cab downward.

Oil Filter - Inspect

• 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 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.

Track (Rubber) - Remove/Replace

• Position the machine on firm, level ground.

• Remove any work tool that is attached to the quick coupler.

• Raise the loader arms and install the brace for the loader lift arm. Refer to Operation and Maintenance Manual, “Loader Lift Arm Brace Operation”.

• Use an appropriate floor jack in order to lift the machine off the ground. Use appropriate jack stands in order to block up the machine.

• Detension the track. Refer to Operation and Maintenance Manual, “Track (Rubber) - Inspect/Adjust”.

• Remove the snap ring (1) and the dust cover (2).

• Remove the nut (3) and the washer (4).

• Thread the cap onto the end of the axle shaft.

• If the cap is not installed, the seal on the wheel will be damaged.

• Use a large mallet in order to strike the inside of the track. This will cause the wheel bearing to pop out of the wheel. The bearing must come out of the wheel in order for the wheel to be removed. A pry bar may be needed in order to remove the wheel completely

• Remove the track.

Window Washer Reservoir - Fill (If Equipped)

• When operating in freezing temperatures, use Caterpillar nonfreezing window washer solvent or equivalent. System damage can result from freezing.

• Fill the reservoir with window washer solvent.

Window Wiper - Inspect/Replace (If Equipped)

• Inspect the condition of the windshield wiper blade. Replace the windshield wiper blade if the windshield wiper blade is worn or damaged. If the window wiper blade streaks the window, replace the window wiper blade.

Windows - Clean (If Equipped)

• Use commercially available window cleaning solutions in order to clean the windows. Clean the outside of the windows from the ground unless handholds are available.