8/24/2016

Language: English
Geographic Region: All
Serial Number Range: SN SLK00001-SLK06999

Caterpillar
257B

Undercarriage Repair Manual

This manual is complements of

TrackLoaderParts.com

The world's best source for Caterpillar

MTL Undercarriage parts.

Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 USA (800)616-815
Undercarriage Repair Manual

Product Safety
The person(s) in charge of servicing a Compact Track
This section contains product safety information for Loader may be unfamiliar with many of the systems on
your Track Loader. Read and under-stand all the machine. This makes it especially important to use
product safety information before attempting to caution when performing service tasks. Familiarize
service any Compact Track Loader. yourself with the affected system(s) and components
before attempting any type of maintenance or service.
Safety Alert Symbol
This symbol means: Attention! It is not possible to anticipate every potential haz-
Be alert! Your safety is ard. The safety messages included in this docu-
involved! ment and displayed on the machine are not all-
inclusive. They are intended to make you aware of
The safety alert symbol is used potential risks and encourage a safe approach to
to alert you to potential personal performing service work. If you use a tool, proce-
injury hazards. Obey all safety messages that follow dure, work method or operating technique that is
this symbol to avoid possible injury or death. not specifically recommended by the manufacturer,
you must satisfy yourself that it is safe for you and
This symbol is used as an attention-getting device others. You must also ensure that the machine will
throughout this manual as well as on decals and labels not be damaged or be made unsafe by the
fixed to the machinery to assist in potential hazard operation, lubrication, maintenance or repair
recognition and prevention. procedures that you choose.
Property or equipment damage warnings in this publi-
cation are identified by the signal word "NOTICE". Basic Precautions
NOTICE Safety Labels
“NOTICE” Indicates a hazardous situation which, Safety labels have been included and are displayed in
if not avoided, could result in property or equip- various places throughout the machine to serve as
ment damage. warnings of potentially dangerous conditions. Read
and understand all "Safety" labels on any Compact
The word “Note” is used throughout this manual to Track Loader before attempting to operate, maintain or
draw your attention to specific topics or to supplement repair it. Replace any damaged, illegible or missing
the information provided in that section. labels immediately, prior to service.
Improper or incomplete maintenance/repair of a
Compact Track Loader can be dangerous and Personal Protective Equipment
may result in machine damage, injury or death. Personal protection equipment is recommended when
performing maintenance or service on a machine.
Do not attempt to perform any type of repair or mainte-
nance on a Compact Track Loader until you have read Always wear appropriate protective equipment for
and fully understood both this manual and the working conditions when working on or around the
machine specific operation and maintenance manual. machine. Loose clothing should not be worn and long
hair should be restrained. Wear hard hats, protective
Refer to the Operation and Maintenance manual for
face/eyewear, safety shoes and any other equipment
instructions regarding proper machine operation and
maintenance techniques before operating or servicing necessary to ensure your safety and the safety of oth-
any Compact Track Loader. ers around you as you work.

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Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 USA (800)616-815
Product Safety

Entering and Exiting Pressurized Items

Always use steps and handholds when entering or 1. Do not use hands or any other body part to check
exiting a Compact Track Loader. Clean any mud or for fluid leaks in the hydraulic system. Always use
debris from steps or work platforms before using them. a solid material like wood or metal to check for this
Always face the machine when using steps and hand- type of leak. Leaking fluid under pressure can pen-
holds. When it is not possible to use the designed etrate body tissue. Fluid penetration can cause
entry/exit system, utilize ladders, scaffolds, or work serious injury and even death. If fluid is injected
platforms to safely gain access to the machine. into your skin, get treatment immediately. Seek
treatment from a doctor that is familiar with this
Lifting type of injury.
Use a hoist when lifting components that weigh 50 lb
(23 kg) or more, to avoid back injury. Make sure all 2. Relieve pressure from the hydraulic system before
chains, hooks, slings, etc., are in good condition and disconnecting or removing any lines, fittings or
are of the correct capacity. Be sure hooks are posi- related items. Do this by relaxing all hydraulic
tioned correctly and equipped with a spring latch. actuators. If the lift arms are raised, make sure
Lifting eyes are not to be side loaded during a lifting they are securely braced. Be alert for possible
operation. pressure release when disconnecting any device
from a pressurized system.
Hot Fluids and Components 3. Lower the lift arms before performing any work on
Stay clear of hot components and system fluids of the the machine. If this cannot be done, make sure
engine, exhaust, radiator/oil cooler and hydraulic they are securely braced to prevent them from
lines/tubes. Also, use caution when removing fill caps, dropping unexpectedly during service.
breathers and plugs on the machine. Hold a rag over
the cap or plug to prevent being sprayed or splashed 4. Loose or damaged fuel, oil, hydraulic, lines, tubes
by liquids under pressure. Be especially careful if the and hoses can cause fires. Do not bend or strike
machine has been operated recently, fluids may still be high pressure lines or install ones that have been
hot. bent or damaged. Check lines, tubes and hoses
carefully. See item 1 for precautions on checking
To ensure your safety, allow the machine to for fluid leaks.
cool before attempting any service proce-
dure that involves hot fluids or components. 5. Pressurized air or water can also cause injury.
When pressurized air or water is used for clean-
Corrosion Inhibitor ing, wear a protective face shield, protective cloth-
Corrosion inhibitor contains alkali. Avoid contact with ing, and protective shoes. The recommended max-
eyes. Avoid prolonged or repeated contact with skin. imum air pressure for cleaning purposes is 30 psi
Do not take internally. In case of contact, wash skin (205 kPa). When using a pressure washer, keep in
immediately with soap and water. For eyes, flush with mind that nozzle pressures are typically very high.
large amounts of water for at least 15 minutes. Call Generally, pressures are well above 2000 psi
Physician. Keep out of reach of children. (13790 kPa). Follow all recommended practices
provided by the pressure washer manufacturer.

Batteries
Do not smoke when inspecting the battery electrolyte
level. Never disconnect any charging unit circuit or bat-
tery circuit cable from the battery when the charging
unit is operating. A spark can cause an explosion from
the flammable vapor mixture of hydrogen and oxygen
that is released from the electrolyte through the battery
outlets. Do not let electrolyte solution make contact
with skin or eyes. Electrolyte solution is an acid. In
case of contact, immediately wash skin with soap and
water. For eyes, flush with large amounts of water for
at least 15 minutes. Call Physician. Keep out of reach
of children.

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Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 USA (800)616-815
Product Safety

Repair 9. Be careful when removing cover plates. Gradually

back off the last two bolts or nuts located on oppo-
Accidental machine starting can cause injury or site sides of the cover. Then, pry the cover loose
even death to personnel working on a Compact to relieve any spring or other pressure before
Track Loader. removing the last two nuts or bolts completely.
As a precaution, disconnect the battery cables from 10. Repairs requiring welding should be performed
the battery terminals, tape the battery clamps and only by personnel adequately trained and knowl-
remove the key from the ignition switch prior to per- edgeable in welding procedures and with the guid-
forming any service work on a Compact Track Loader. ance of appropriate reference information.
Place a “Do Not Operate” tag prominently on the Determine the type of metal being welded and
machine to inform personnel that the machine is being select the correct welding procedure and filler
serviced. material to provide a weld that is as strong or
stronger than the original weld.
1. Disconnect the battery and discharge any capaci- NOTICE
tor before beginning work on a machine. Attach a
Do Not Operate tag in the cab to alert any opera- Prior to welding, disconnect the following to pre-
tor that service is in progress. vent component damage:
2. If possible, make all repairs with the machine • Negative battery cable
parked on a level, hard surface. Use blocks to pre- • Engine ECU (firewall)
vent the machine from rolling while working on or • Main controller (firewall)
under the machine. • Output module (firewall)
• Display (machine)
3. Do not work on or under any machine that is sup-
ported only by a hydraulic jack or hoist. Always A proper ground is essential to protect the
use suitable mechanical supports to ensure that machine from damage when welding. Improper
the machine will not fall. grounding can cause damage to mechanical,
4. Make sure the work area around the machine is hydraulic and electrical components.
safe and make yourself aware of any hazardous As a precaution, connect the welding ground
conditions that may exist. If the engine needs to clamp as close as possible to the weld area.
be started inside an enclosure, make sure that the
engine’s exhaust is properly vented. 11. Take precautions to avoid damaging wiring during
removal and installation operations. Carefully route
5. Be sure all protective devices including guards and
wires so that they will not contact sharp corners,
shields are properly installed and functioning cor-
objects or hot surfaces during operation.
rectly before beginning any service task. If a guard
or shield must be removed to perform the repair 12. When performing service that requires the lift arms
work, use extra caution. to be in the raised position, always utilize the lift
arm brace located on the rear of the loader tower.
6. Always use the appropriate tools for the work to be
performed. Tools should be in good condition and 13. Relieve hydraulic system pressure by relaxing all
you should understand how to use them properly hydraulic actuators prior to attempting any
before performing any service work. hydraulic maintenance or repair.
7. When replacing fasteners, use parts of equivalent 14. Always tighten connections to the correct torque
grade and size. Do not use a lesser quality fasten- specification. Make sure that all shields, clamps
er if replacements are necessary. and guards are installed correctly to avoid exces-
sive heat, vibration or unwanted contact between
8. Be prepared to stop an engine if it has been re-
parts during operation. Shields that protect
cently overhauled or the fuel system has been
exhaust components from oil spray in event of a
recently serviced. If the engine has not been
line, tube or seal failure must be correctly installed.
assembled correctly, or if the fuel settings are not
correct, the engine can possibly overspeed and 15. Do not operate a machine if any rotating part is
cause bodily injury, death or property damage. Be damaged or contacts other parts during operation.
prepared to shut off the fuel and air supply to the Any high speed rotating component that has been
engine in order to stop the engine. damaged or altered should be checked for balance
before reusing. Make sure all protective devices,
including guards and shields, are properly installed
and functioning correctly before starting the engine
or operating the machine.

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Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 USA (800)616-815
Product Safety

Attachments Safety Label Examples

Only use compatible attachments as defined by the Examples of the labels and decals displayed on the
machine specific operation and maintenance manual. machine are shown on this page.

Make sure that all necessary guards and protective

equipment are in place and functioning prior to operat-
ing any attachment.

Wear protective glasses and protective equipment as Crush Hazard

Death or serious injury can result
required by conditions or as recommended in the from contact with moving lift arm or
attachment.
Keep clear of lift arms and
attachments.

attachment’s operation manual.

2030-592

When replacement parts are required for your

machine, use only genuine OEM replacement
parts or parts that meet or exceed original
specifications including, but not limited to physical
dimensions, type, strength and material.
CRUSH HAZARD
Contact with moving machine can Keep clear of moving machine.
Installing lesser components can lead to premature result in death or serious injury. 2030-593

failures, product damage, personal injury or death.

Ensure that all personnel are far enough away from

the work area so they will not be struck by flying ob-
jects.
Fall Hazard

Stay clear of the cutting edges, pinching surfaces or

Use the provided access system when
Serious injury or death can result
entering or exiting the machine.
from falling.

crushing surfaces of the attachment while performing

2030-597

any attachment maintenance, testing or adjustments.

Machine Labels and Decals • Relieve internal pressure before

disconnecting any line or fitting.
• Keep away from leaks or pinholes.
• Use cardboard to check for leaks.

Labels and decals placed on the machine provide Injection Hazard

Fluid injected into skin must be surgi-
cally removed within a few hours by a

safety information and operating instructions.

Escaping fluid under pressure can doctor familiar with this type of injury
penetrate skin, causing serious injury. or gangrene will result. 2030-602

Familiarize yourself with the location and significance

of these labels to ensure your safety.

Crush Hazard
Death or serious injury can result
from contact with moving lift arm or Install lift arm brace prior to servicing.
attachment. 2030-594

Keep away from fan and belt while the

Entanglement Hazard engine is running. Stop engine before
Rotating parts can cause personal injury. servicing.
2030-600

Burn Hazard Allow the machine to cool thoroughly

Hot fluid under pressure can scald. before opening.
2030-595

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Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 USA (800)616-815
Product Safety

Jacking Procedure
Occasionally, your machine may need to be suspend-
ed off of the ground to perform maintenance. Exercise
Improper operation or maintenance
caution when jacking the machine. Always use a jack
of this equipment can result in
death or serious injury.
Crush Hazard that is capable of lifting the machine and support its
Machine rollover can result in
death or serious injury. weight with suitable mechanical supports while sus-
pended. Never work on or under a machine supported
Read and understand operator’s only by a jack.
manual and all safety signs before
using or maintaining machine. Always fasten seat belt. Keep all
If you do not understand the
body parts inside the operator
enclosure at all times.
To safely jack your machine:
information in the manuals, consult
your supervisor, the owner or the 1. Remove any attachments that may be fastened to
manufacturer.
the machine and raise the lift arms.
2. Install the lift arm brace according to manual.
3. Once the lift arms are secured, carefully exit the
machine.
Fall Hazard
Fall Hazard Falling can result in death or
serious injury.
4. Roll or slide your jack under the front of the
Falling can result in death or
serious injury. machine and center the lifting pad directly under
the middle of the front torsion axle.
5. Once in place, jack the machine upward making
No Riders sure it remains stable until it has reached sufficient
Stay off of bucket or attachment.
2046-299 height to install suitable mechanical supports
beneath the machine.

Mechanical supports may not be placed

Rollover Hazard beneath the belly pans as they are not
Overturning this machine can
Fire Hazard
Flammable debris can collect near result in death or serious injury. designed to support the weight of the machine.
hot components and lead to a fire. They must be placed beneath the torsion axles or
beneath the perimeter chassis tubes only.
Carry
Ca
arry loads low
low..

Read Operator’s Manual

Carry loads low. Load unload and
turn on level ground. Travel on
6. Slide the support(s) into place making sure they
Keep the engine, exhaust and
chassis areas free of debris.
inclines with heaviest end of are placed in such a way that the machine remains
machine uphill. 2046-300
stable when the jack is lowered and the front of the
chassis rests on the supports.
7. Once the supports are in place, slowly lower the
machine onto them and then remove the jack.
Repeat steps 4-7 at the rear of the machine should
both ends of the machine need to be off of the ground
Explosion/Burn Hazard
Will cause death, burns or for service.
blindness due to ignition of Burn Hazard
explosive gasses or contact Contact with hot surfaces can
with corrosive acid. cause burns.

• Keep all flames/sparks

away! • Do not touch hot
• No Smoking! components!
• Read and understand • Allow the machine to
all manuals prior to cool thoroughly prior to
operation. 2030-603 servicing. 2030-601

5
Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 USA (800)616-815
Undercarriage Disassembly and Assembly

Undercarriage Disassembly and Assembly

Personal Safety Undercarriage Disassembly

Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in
and Assembly Procedures
machine damage, injury or death. Disassembly and assembly procedures are
provided for the following undercarriage
Do not attempt to perform any type of repair or components.
maintenance on a Compact Track Loader until you have
read and fully understood the information in this manual. • Center wheels
Refer to the Operation and Maintenance manual for • End wheels
instructions regarding proper machine operation • Sprocket rollers
techniques before operating any Compact Track Loader.
• Tracks
Prior to performing any type of service work on a
Compact Track Loader, read and understand • Outboard bearings
Pages 1-5 (Product Safety) for personal safety • Drive sprockets
information.
• Drive motors

Machine Preparation
Note: Procedures are provided for only those
Accidental machine starting can cause injury or undercarriage components listed above. However, other
death to personnel working on a Compact Track helpful information can be obtained from the Compact
Loader. Track Loader Parts Manual.

As a precaution, disconnect the battery cables from

the battery terminals, tape the battery clamps and
remove the key from the ignition switch prior to
performing any service work on a Compact Track
Loader. Center Wheel Removal and
Place a “Do Not Operate” tag prominently on the Installation
machine to inform personnel that the machine is
being worked on. The tools required for wheel removal and
installation are listed in Table 1. Use manufacturer-
recommended tools whenever possible.

Table 1: Required Tools

Wheel Extractor
Channel Lock Pliers
Socket Wrench
Screw Driver

NOTE: This manual covers several different models.

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Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 USA (800)616-815
Undercarriage Disassembly and Assembly

Wheel Removal
1. Locate the wheel cap snap ring.

Figure 4

4. Using a socket, remove the nut that fastens the

wheel to the shaft. Remove the wheel with the
Figure 1 wheel extractor.

Inside Wheel
2. Use a screw driver to remove the snap ring that
secures the wheel cap.

Figure 5

5. To remove an inside wheel, slide under the

Figure 2
machine and repeat the wheel removal
procedure.

3. Using a large channel lock pliers, remove the

wheel cap.

Figure 6

Figure 3
6. With wheels removed, inspect the bearings and
axle for wear or damage.

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Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 USA (800)616-815
Undercarriage Disassembly and Assembly

End Wheels
The tools required for wheel removal and installation
are listed in table 2. Use manufacturer recommended
tools whenever possible.
Table 2: Required Tools
Heavy duty hydraulic jack
Combination wrench
Suitable mechanical supports (2)
Wheel Extractor
Channel Lock Pliers
Socket Wrench
Screw Driver

Removal

Figure 9

3. Use a screw driver to remove the snap ring that

secures the wheel cap.

Figure 7

1. Raise and support the machine on Suitable

mechanical supports in the front and rear.

Figure 10

4. Using Large Channel Lock Pliers, Remove The

Snap Ring

Figure 8

2. Clean the threads with a plastic or wire bristle

brush, then loosen the turnbuckle as shown to
lower the drive table and create slack in the track. Figure 11

5. Using a socket, remove the nut that fastens the

wheel to the shaft. Remove the wheel with the
wheel extractor.
6. Slide the track outward as you pull on the wheel to
remove the wheel.
7. With wheels removed, inspect the bearings and
axle for wear or damage. See Figure 6, Page 7

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Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 USA (800)616-815
Undercarriage Disassembly and Assembly

Sprocket Rollers Track Removal and Installation

The tools required for sprocket roller removal and The tools required for track removal and installation
installation are listed in table 3. Use manufacturer are listed in table 4. Use manufacturer recommend-ed
recommended tools whenever possible. tools whenever possible.

Table 3: Required Tools Table 4: Required Tools

Combination/Socket Wrench Socket/impact wrench
Heavy duty hydraulic jack
Combination wrench
Ring Retaining Suitable mechanical supports)
Bolt

Removal
1. Perform the end wheel removal procedure located
on page 8 of this section.
Drive
Roller Table

Steel Pin

Figure 12

Figure 14
2. Once the wheel has been removed, pull the track
off of the front of the undercarriage, then lift over
the drive sprocket and off of the rear of the under-
carriage to remove.

Installation
Figure 13
1. Position the sprocket so that you can easily access
one bolt/roller/pin assembly. With the engine off
and controls in neutral, remove the retaining bolt
and with it the roller and steel pin.

2. Inspect the pin and roller for wear or cracking and

replace as necessary. If any of the rollers show
signs of wear through or cracking, replace them. If
the pins are worn or cracked, replace them as
well.

Note: Replace rollers and pins (if necessary) as a set.

This will simplify future inspection and minimize redun- Figure 15
dant maintenance. 1. To install the track, reverse the removal procedure.

Note: When installing the track it is helpful to lubricate

the inner front wheel surface to help slide the track into
position.

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Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 USA (800)616-815
Undercarriage Disassembly and Assembly

Outboard Bearing Removal and

Installation
The tools required to remove and install the outboard
bearing assembly are listed in table 5. Use manu-
facturer recommended tools whenever possible.

Table 5: Required Tools

Combination/socket wrench
Snap ring pliers
Puller
Hammer/chisel Figure 18
3. Use a hammer to drive a screwdriver in along the
Removal edge of the rubber cap. the pry the cap out as
shown. (the cap must be replaced after service)

Figure 16
1. Remove the four bolts securing the bearing to the
Figure 19
mounting plate.
4. Use a snap ring pliers to remove the snap ring
retainer from the shaft as shown.

Figure 17
Figure 20
2. Remove the 3 bolts securing the mounting plate to
5. Use a puller to remove the bearing assembly from
the drive table, then use a chisel to gently sepa-
the machine as shown.
rate the two components. Remove the mounting
plate from the machine.
Installation
1. To install the outboard bearing, reverse the
removal procedure.

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Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 USA (800)616-815
Undercarriage Disassembly and Assembly

Drive Sprocket Removal and Drive Motor Removal and

Installation Installation
The tools required to remove and install the drive The tools required to remove and install the drive
sprocket assembly are listed in table 6. Use manu- motor are listed in table 7. Use manufacturer rec-
facturer recommended tools whenever possible. ommended tools whenever possible.

Table 6: Required Tools Table 7: Required Tools

Combination/socket wrench Combination/socket wrench
Snap ring pliers Crow’s foot
Puller
Hammer/chisel Removal
1. Perform the drive sprocket removal procedure as
Removal described on this page.
1. Perform the outboard bearing removal procedure
as described on page 10 of this manual.

Figure 21

2. Remove the bolts securing the drive motor to the

Figure 21 drive table as shown.

2. Remove the nuts securing the sprocket to the drive

motor, then carefully remove the drive sprocket.

Installation
1. To install the drive sprocket, reverse the removal
procedure.

Figure 22

3. Disconnect the various hoses from the drive motor

(noting their positions and orientations for
reassembly), then remove the drive motor from the
machine. (cap or plug all tubes/hoses/fittings)

Installation
1. To install the drive motor, reverse the removal pro-
cedure.

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Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 USA (800)616-815
Maintenance

Track Tension Checking for Proper Track Adjustment

Proper track tension is very important for optimum 1. Drive the machine forward five feet to remove
performance and long track life. Tracks that are run any slack from the lower and rearward portions
too loose can cause misfeeding and ratcheting pos- of the track.
sibly causing damage to the track. During the first 50
hours of operation, the tracks will “break in” and will
most likely require adjustment.

Track Tension Adjustment Procedures

Jam
Nut

Track Figure 25
Tensioner
2. Lay a straightedge along the top of the track be-
tween the sprocket and the front idler wheel.
Figure 23 3. Using a rope or wire, put 50 pounds (23 kg) of
down force on the track at the midpoint of the
1. Locate the jam nut on the track tensioner and straightedge.
clean the threads thoroughly before proceeding.
2. Loosen the jam nut. You can use the wrench
supplied with the machine, but a standard
wrench is preferred for shop use.

Figure 26

4. Using a ruler, measure the distance between the

straightedge and track. The track should not de-
Figure 24
flect more than 0.75” (1.9 cm) between the top
of the track and the straightedge.
3. After loosening the jam nut, turn the track ten- 5. If the track deflects more than 0.75” (1.9 cm),
sioner until the track tension is within specifica- tighten the track between 0.50” (1.3 cm) and
tions. 0.75” (1.9 cm).
4. Once proper tension is achieved, retighten the
jam nut Trouble Shooting: Track makes popping noise.
Probable Cause:
1. Track too loose. (Refer to track adjustment section.)
2. Worn or stuck drive teeth. Outer roller should pivot
as lug comes into sprocket.
3.. Lo e or worn sprocket.
4. Worn track lugs.
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Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 USA (800)616-815