MAINTENANCE INTERVALS

Operation and Maintenance

Manual Excerpt

® ®
© 2010 Caterpillar
All Rights Reserved
 KEBU7543-08
August 2012

Operation and
Maintenance
Manual
CS56, CS64, CS74, CS76, CP56,
CP64, CP74 and CP76 Vibratory Soil
Compactors
C5S1-Up (CS56)
FCS1-Up (CS56)
C7F1-Up (CS64)
C6S1-Up (CS64)
C8F1-Up (CS74)
C8S1-Up (CS74)
JCS1-Up (CS76)
CYX1-Up (CS76)
FCP1-Up (CP56)
C5P1-Up (CP56)
P7F1-Up (CP64)
C6P1-Up (CP64)
P8F1-Up (CP74)
C8P1-Up (CP74)
C7L1-Up (CP76)
JCP1-Up (CP76)

SAFETY.CAT.COM
88 KEBU7543-08
Maintenance Section
Maintenance Interval Schedule

i04982169 Every 10 Service Hours or Daily

Maintenance Interval Schedule Backup Alarm - Test .............................................. 91
Cooling System Coolant Level - Check ................ 96
SMCS Code: 1000; 7000 Engine Air Filter Service Indicator - Inspect ........ 107
Engine Oil Level - Check .................................... 108
Ensure that all safety information, warnings, and Hydraulic System Oil Level - Check .................. 121
instructions are read and understood before any Indicators and Gauges - Test .............................. 123
operation or any maintenance procedures are Neutral Start Switch - Test .................................. 124
performed. Seat Belt - Inspect .............................................. 128

The user is responsible for the performance of Every 50 Service Hours or Weekly
maintenance. All adjustments, the use of proper
lubricants, fluids, filters, and the replacement of Fuel Tank Water and Sediment - Drain ................ 118
components due to normal wear and aging are Leveling Blade - Lubricate .................................. 123
included. Failure to adhere to proper maintenance Steering Cylinder Ends - Lubricate ..................... 130
intervals and procedures may result in diminished Tire Inflation - Check ........................................... 131
performance of the product and/or accelerated wear
of components. Initial 250 Service Hours

Use mileage, fuel consumption, service hours, or Axle Oil (Rear) - Change ...................................... 90
calendar time, WHICH EVER OCCURS FIRST, Axle Oil (Rear) - Change ...................................... 90
in order to determine the maintenance intervals. Final Drive Planetary (Axle) Oil - Change ............ 111
Products that operate in severe operating conditions Final Drive Planetary (Drum) Oil - Change .......... 112
may require more frequent maintenance. Refer to the Vibratory Support Oil - Change ........................... 133
maintenance procedure for any other exceptions that
may change the maintenance intervals. Every 250 Service Hours
Cooling System Coolant Sample (Level 1) -
Note: Before each consecutive interval is performed,
Obtain ................................................................. 97
all maintenance from the previous interval must be
performed.
Every 250 Service Hours or 3 Months
When Required Axle Oil Level (Rear) - Check ............................... 91
Belts - Inspect/Adjust/Replace .............................. 92
Battery - Clean/Check ........................................... 91 Engine Oil Sample - Obtain ................................ 108
Battery - Recycle .................................................. 92
Final Drive Planetary (Axle) Oil Level - Check ..... 111
Battery or Battery Cable - Inspect/Replace .......... 92
Final Drive Planetary (Drum) Oil - Check ............ 113
Cab Air Filter - Clean/Replace .............................. 93 Vibratory Support Oil Level - Check ................... 133
Circuit Breakers - Reset ........................................ 93
Cutting Edges (Leveling Blade) - Inspect/
Replace ............................................................. 100
Initial 500 Hours (for New Systems, Refilled
Drum Cooling Oil - Change ................................. 101 Systems, and Converted Systems)
Drum Scrapers - Inspect/Adjust/Replace ............ 101 Cooling System Coolant Sample (Level 2) -
Engine Air Filter Primary Element - Clean/ Obtain ................................................................. 98
Replace ............................................................. 105
Engine Air Filter Secondary Element - Replace .. 107
Every 500 Service Hours or 6 Months
Fuel System - Prime ............................................ 114
Fuses - Replace ................................................... 119 Axle Oil Sample - Obtain ...................................... 91
Oil Filter - Inspect ................................................ 125 Engine Oil and Filter - Change ........................... 109
Propel Control Tension - Adjust .......................... 126 Fuel System Primary Filter (Water Separator) -
Radiator Core - Clean ......................................... 127 Replace .............................................................. 114
Tire Spacing - Change ........................................ 132 Fuel System Secondary Filter - Replace ............. 116
Wheel Nuts - Tighten .......................................... 134 Hydraulic System Oil Sample - Obtain ............... 122
Wheel Nuts - Tighten .......................................... 135 Parking Brake - Check ........................................ 125
Window Washer Reservoir - Fill .......................... 135 Shell Kit Bolt Torque - Check .............................. 129
Window Wiper - Inspect/Replace ........................ 135 Vibratory Support Oil Sample - Obtain ............... 134
Windows - Clean ................................................. 135
Every 1000 Service Hours or 1 Year
Initial 10 Service Hours
Axle Oil (Rear) - Change ...................................... 90
Shell Kit Bolt Torque - Check .............................. 129 Axle Oil (Rear) - Change ...................................... 90
Cooling System Pressure Cap - Clean/Replace ... 98
KEBU7543-08 89
Maintenance Section
Maintenance Interval Schedule

Engine Valve Lash - Check/Adjust ....................... 110

Final Drive Planetary (Axle) Oil - Change ............ 111
Final Drive Planetary (Axle) Oil Sample - Obtain .. 112
Final Drive Planetary (Drum) Oil - Change .......... 112
Final Drive Planetary (Drum) Oil Sample -
Obtain ................................................................ 113
Fuel Tank Cap and Strainer - Clean .................... 117
Hydraulic System Oil Filter - Replace ................. 121
Hydraulic Tank Breather - Replace ..................... 122
Isolation Mounts - Inspect/Replace ..................... 123
Rollover Protective Structure (ROPS) - Inspect .. 127
Vibratory Support Oil - Change ........................... 133

Every 2000 Service Hours or 1 Year

Hydraulic System Oil - Change ........................... 120

Every Year
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 98

Every 3000 Service Hours

Steering Column Spline (HMU Steering) -
Lubricate ........................................................... 129

Every 3000 Service Hours or 18 Months

Hydraulic System Oil - Change ........................... 120

Every 3000 Service Hours or 2 Years

Cooling System Water Temperature Regulator -
Replace ............................................................... 99

Every 3 Years
Seat Belt - Replace ............................................. 128

Every 3000 Service Hours or 3 Years

Eccentric Weight Housing Oil - Change ............. 102

Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .... 95

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 94
90 KEBU7543-08
Maintenance Section
Axle Oil (Rear) - Change

i02527718 i02820506

Axle Oil (Rear) - Change Axle Oil (Rear) - Change

SMCS Code: 3260-044; 3278-044; 3278 SMCS Code: 3260-044; 3278-044; 3278
S/N: C7F1-Up S/N: P7F1-Up
S/N: C8F1-Up S/N: P8F1-Up
S/N: C5P1-Up S/N: C7L1-Up
S/N: FCP1-Up S/N: C6P1-Up
S/N: C5S1-Up S/N: C8P1-Up
S/N: C6S1-Up S/N: JCP1-Up
S/N: C8S1-Up S/N: JCS1-Up
S/N: FCS1-Up S/N: CYX1-Up

g01264601 g01407556
Illustration 107 Illustration 108

1. Remove differential drain plug (1). The plug is

located on the back side of the differential case
at the bottom.

Note: Drain the oil into a suitable container. Dispose

of the used oil in an appropriate manner.

2. Remove differential level/fill plug (2). Differential

level/fill plug (2) is located on the back side of the
differential case.

3. Clean drain plug (1) and install drain plug (1). Add
the proper oil to the differential. Maintain the level
of the oil to the bottom of the hole for differential g01407573
level/fill plug (2). Refer to the Operation and Illustration 109
Maintenance Manual, “Lubricant Viscosities and
Capacities (Refill)” section for more information. 1. Remove the differential drain plug (1). The plug is
located on the front side of the differential case
4. Clean the filler plug. Install the filler plug. at the bottom.

Note: Drain the oil into a suitable container. Dispose

of the used oil in an appropriate manner.

2. Remove the differential level/fill plug (2). The

differential level/fill plug is located on the back
side of the differential case.
KEBU7543-08 91
Maintenance Section
Axle Oil Level (Rear) - Check

3. Clean the drain plug and install the drain plug. The backup alarm should start to sound immediately.
Add the proper oil to the differential. Maintain The backup alarm will continue to sound until the
the level of the oil to the bottom of the hole transmission control lever is moved to the STOP
for the differential level/fill plug. Refer to the position or to the FORWARD position.
Operation and Maintenance Manual, “Lubricant
Viscosities and Capacities (Refill)” section for
more information.

4. Clean the filler plug. Install the filler plug.

i01849999

Axle Oil Level (Rear) - Check

SMCS Code: 3260-535-FLV; 3278-535; 3278

Note: Always check the oil level when the machine is

parked on a level surface.
g00930005
Illustration 110
Note: The differential level/fill plug is located on the
back side of the rear axle.
If the backup alarm does not sound, make the
necessary repairs immediately. Do not operate a
1. Remove the level/fill plug. Maintain the oil level
machine without a backup alarm.
to the bottom of the level/fill plug opening. If
necessary, add oil.
i02539407
Note: When you add oil, allow the oil to settle in
order to verify the oil level. Battery - Clean/Check
2. Clean the level/fill plug. Install the plug. SMCS Code: 1401-070; 1401-535; 1402-070;
1402-535
i01830493

Axle Oil Sample - Obtain

SMCS Code: 3260-008; 3278-008; 7542

Obtain an oil sample of the differential oil through the

oil level/fill plug. The oil level/fill plug is located on the
back side of the rear axle.

Refer to the Special Publication, SEBU6250, “Cooling

System specifications” and refer to the Operation
and Maintenance Manual, “Sampling Interval and
Location of Sampling Valve” for more information.
g01272574
Illustration 111
i02855591
Note: The batteries that are supplied with the
Backup Alarm - Test machines are maintenance free batteries. You do
not need to check the level of the electrolyte in the
SMCS Code: 7406-081 maintenance free batteries.

The backup alarm is located at the rear of the Tighten the battery retainers (2) on both of the
machine. batteries. Tighten the battery retainers at every 1000
hours.
Turn the engine start switch to the ON position in
order to perform the test. Check the following items at every 1000 hours. If
necessary, check the following items more often.
Move the propel control lever to the REVERSE
position. • Clean the top of the batteries with a clean cloth.
92 KEBU7543-08
Maintenance Section
Battery - Recycle

• Clean the battery terminals (1). As needed, coat 8. Remove the cable from the positive terminal on the
the battery terminals with petroleum jelly. second battery. The cable connects the positive
terminal of the second battery to the starter.
i00993589
9. Remove the cable from the negative terminal
Battery - Recycle of the first battery. The cable connects the first
battery negative terminal to the disconnect switch.
SMCS Code: 1401-561
10. Remove the cable from the starter.
Always recycle a battery. Never discard a battery.
11. Perform the necessary repairs. Replace the
Always return used batteries to one of the following cables or the batteries, as needed.
locations:
12. Reverse the above steps in order to reconnect
the batteries.
• A battery supplier
13. Connect the battery cable at the battery
• An authorized battery collection facility disconnect switch.
• Recycling facility 14. Install the battery disconnect switch key. Turn the
battery disconnect switch to the ON position.
i03629796
15. Install the battery compartment cover.
Battery or Battery Cable -
Inspect/Replace i02539415

SMCS Code: 1401-040; 1401-510; 1402-040; Belts - Inspect/Adjust/Replace

1402-510
SMCS Code: 1357-025; 1357-040; 1357-510
1. Turn the engine start switch to the OFF position.
Turn all switches to the OFF position. Your engine is equipped with one belt to run the
alternator and the A/C compressor (if equipped).
2. Turn the battery disconnect switch to the OFF
position. Remove the battery disconnect switch
key.

3. Open the battery compartments. There is one

compartment at the rear of the machine.

4. At the battery disconnect switch, disconnect the

negative battery cable that is connected to the
frame.

Note: Do not allow the disconnected battery cables

to contact the disconnect switch. Do not allow the
disconnected battery cables to contact the other
cables. Do not allow the disconnected battery cables
g01272591
to contact the opposite terminal of either battery. Illustration 112
Alternator Belt with A/C
5. Disconnect the negative battery cable at the
battery.

6. Disconnect the positive terminal of the cable that

connects the batteries from the first battery.

7. Remove the negative terminal of the cable that

connects the two batteries from the second
battery.
KEBU7543-08 93
Maintenance Section
Cab Air Filter - Clean/Replace

g01272592 g00645580
Illustration 113 Illustration 115
Alternator Belt without A/C
3. Clean air filters (3) with a maximum of 200 kPa
Inspect the condition of the belt for wear and damage. (30 psi).
The belt is self-adjusting for proper tension. No
measuring or adjustment is required. 4. After you clean the air filters, inspect the air
filters. If the air filters are damaged or badly
If installation of a new belt is required, refer to contaminated, use new air filters.
Disassembly and Assembly, KENR6004, “CP/CS-56,
CP/CS-64, CP/CS-74 Vibratory Compactors” or 5. Install the filters in the reverse order of the above
Disassembly and Assembly, KENR6413, “CP/CS-76 steps.
Vibratory Compactors”.
i02539019
i01773798
Circuit Breakers - Reset
Cab Air Filter - Clean/Replace
SMCS Code: 1420-529
SMCS Code: 7311-040; 7311-070-FI; 7311-070;
7311-510-FI; 7311; 7342-070-FI; 7342-070; The circuit breaker panel is located in the engine
7342-510-FI; 7342-510; 7342; 7521 compartment.

The cab air filter is located to the left of the seat.

g01272919
Illustration 116

g00645572
Illustration 114 Circuit Breaker/Reset – Push in the button
in order to reset the circuit breaker. If the
1. Remove two hand knobs (1). electrical system is functioning properly, the
button will remain depressed. If the button does not
2. To remove the air filters, pull upward on handle (2). remain depressed, check the appropriate electrical
circuit. Repair the electrical circuit, if necessary.
94 KEBU7543-08
Maintenance Section
Cooling System Coolant (ELC) - Change

Breaker for the Glow Plugs (1)

Personal injury can result from hot coolant, steam
and alkali.

Breaker for the Alternator (2) 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.
Main Breaker (3)
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.
Breaker for the ECM (4)
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
i03303240
Cooling System Coolant Additive contains alkali.
Cooling System Coolant (ELC) Avoid contact with skin and eyes.
- Change
3. Slowly loosen cooling system pressure cap (1)
SMCS Code: 1395-044-NL on the radiator. Slowly remove cooling system
pressure cap (1).
Drain the coolant whenever the coolant is dirty. Drain
the coolant when foam is observed. 4. Remove the cap for the cooling system expansion
tank (2).
1. Stop the engine. Allow the cooling system to cool
completely. NOTICE
Care must be taken to ensure that fluids are contained
2. Open the engine compartment. 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.

5. Drain valve (3) is located on the bottom corner

g01272608 of the radiator. Open drain valve (3). Allow the
Illustration 117
coolant to drain into a suitable container.

6. Close drain valve (3). Fill the radiator with a

solution which consists of clean water and of
cooling system cleaner. Once the radiator is filled,
fill the cooling system expansion tank to the full
line. 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.

KEBU7543-08 95
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

8. Stop the engine. Allow the cooling system to 14. Start the engine. Run the engine without cooling
cool completely. Open drain valve (3). Drain the system pressure cap (1) until the thermostat
cleaning solution into a suitable container. opens and the coolant level stabilizes.

9. While the engine is stopped, flush the system with Note: If the machine is equipped with a cab heater
water. Flush the system until the draining water the temperature control must be turned to the hot
is transparent. position when the engine is running. Turning the
temperature control to the hot position will ensure
10. Close drain valve (3). that the lines and the core are full of coolant.

NOTICE 15. Maintain the level of the coolant to the top of the
Mixing Extended Life Coolant (ELC) with other prod- radiator and to the full line on the expansion tank.
ucts reduces the effectiveness of the coolant and
shortens coolant life. Use only Caterpillar prod- 16. Replace cooling system pressure cap (1) if
ucts or commercial products that have passed the the gasket is damaged. Install cooling system
Caterpillar EC-1 specifications for premixed or con- pressure cap (1) and the cap for the expansion
centrate coolants. Use only Caterpillar Extender with tank (2).
Caterpillar ELC. Failure to follow these recommenda-
tions could result in the damage to cooling systems 17. Stop the engine.
components.
18. Close the engine compartment.
If ELC cooling system contamination occurs, refer to
Operation and Maintenance, “Extended Life Coolant i03303409
(ELC)” under the topic ELC Cooling System Contam-
ination. Cooling System Coolant
Extender (ELC) - Add
11. Add the coolant solution. See the following topics:
SMCS Code: 1352-544-NL
• Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations”, “Cooling
System Specifications”
At operating temperature, the engine coolant is
• Operation and Maintenance Manual, “Capacities hot and under pressure.
(Refill)”
Steam can cause personal injury.
Note: If you are using Caterpillar antifreeze, do not
add the supplemental coolant additive at this time
Check the coolant level only after the engine has
and/or change the element at this time.
been stopped and the fill cap is cool enough to
touch with your bare hand.
12. Slowly add coolant to radiator (1) until the coolant
reaches the top. The radiator should be filled no
Remove the fill cap slowly to relieve pressure.
faster than five liters per minute.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent personal
injury.

When a Caterpillar Extended Life Coolant (ELC) is

used, an Extender must be added to the cooling
system.

Use a 8T-526 Coolant Test Kit to check the

concentration of the coolant.

Refer to the Special Publication, SEBU6250,

“Caterpillar Machines Fluids Recommendations”,
“Cooling System Specifications” for more information
g01272614
Illustration 118 about the addition of Extender.

13. Add coolant to expansion tank (2) until the coolant

reaches the full line.
96 KEBU7543-08
Maintenance Section
Cooling System Coolant Level - Check

NOTICE
Topping off or mixing Cat ELC with other products that
do not meet Caterpillar EC-1 specifications reduces
the effectiveness of the coolant, shortens coolant ser-
vice life, and may cause premature wear to compo-
nents.

Use only Caterpillar products or commercial products

that have passed the Caterpillar EC-1 specification for
pre-mixed or concentrate coolants. Use only Extender
with Cat ELC.

Failure to follow these recommendations can result in

shortened cooling system component life. g01272614
Illustration 120

1. Stop the engine. Allow the cooling system to 6. Maintain the level of the coolant to the top of the
completely cool. radiator and to the full line on the expansion tank.

2. Open the engine compartment. 7. Inspect the gasket on the cooling system pressure
cap. Replace the cooling system pressure cap if
the gasket is damaged.

8. Install the cooling system pressure cap.

9. Close the engine compartment.

i03303421

Cooling System Coolant Level

- Check
SMCS Code: 1350-535-FLV
g01272622
Illustration 119

3. Slowly loosen the cooling system pressure cap At operating temperature, the engine coolant is
in order to relieve system pressure. Remove the hot and under pressure.
cooling system pressure cap.
Steam can cause personal injury.
4. If necessary, drain enough coolant from the
radiator in order to allow the addition of the Check the coolant level only after the engine has
Extender. been stopped and the fill cap is cool enough to
touch with your bare hand.
5. Add the recommended amount of extender
to the coolant system. Refer to the Special Remove the fill cap slowly to relieve pressure.
Publication, SEBU6250, “Caterpillar Machines
Fluids Recommendations”, “Cooling System Cooling system conditioner contains alkali. Avoid
Specifications” for the proper amount. contact with the skin and eyes to prevent personal
injury.

1. Open the engine compartment.

KEBU7543-08 97
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain

• Commercial long life coolants that meet the

Caterpillar Engine Coolant Specification -1
(Caterpillar EC-1)

• Cat Diesel Engine Antifreeze/Coolant (DEAC)

• Commercial heavy-duty antifreeze/coolant

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-
Illustration 121
g01272622 rect interpretation that could lead to concerns by both
dealers and customers.

Note: Level 1 results may indicate a need for

Level 2 Analysis.

g01272614
Illustration 122

2. Maintain the level of the coolant to the top of the

radiator and to the full line on the expansion tank.
g01273207
Illustration 123
3. Close the engine compartment.
The coolant sample port is located on the left side of
i02539428
the machine above the alternator.

Cooling System Coolant Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order
Sample (Level 1) - Obtain to receive the full effect of S·O·S analysis, you
must establish a consistent trend of data. In order
SMCS Code: 1350-008; 1395-008; 1395-554; to establish a pertinent history of data, perform
7542-008; 7542 consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
Note: It is not necessary to obtain a Coolant your Caterpillar dealer.
Sample (Level 1) if the cooling system is filled
with Cat ELC (Extended Life Coolant). Cooling Use the following guidelines for proper sampling of
systems that are filled with Cat ELC should have the coolant:
a Coolant Sample (Level 2) that is obtained at
the recommended interval that is stated in the
Maintenance Interval Schedule.
• Complete the information on the label for the
sampling bottle before you begin to take the
samples.
Note: Obtain a Coolant Sample (Level 1) if the
cooling system is filled with any other coolant
instead of Cat ELC. This includes the following
• Keep the unused sampling bottles stored in plastic
bags.
types of coolants.
• Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
from any other location.
98 KEBU7543-08
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain

• Keep the lids on empty sampling bottles until you Refer to Operation and Maintenance Manual,
are ready to collect the sample. “Cooling System Coolant Sample (Level 1) - Obtain”
for the guidelines for proper sampling of the coolant.
• Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid Submit the sample for Level 2 analysis.
contamination.
For additional information about coolant analysis, see
• Never collect samples from expansion bottles. Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” or consult your Caterpillar
• Never collect samples from the drain for a system. dealer.

Submit the sample for Level 1 analysis.

i02539442

For additional information about coolant analysis, see

Special Publication, SEBU6250, “Caterpillar Machine
Cooling System Pressure Cap
Fluids Recommendations” or consult your Caterpillar - Clean/Replace
dealer.
SMCS Code: 1382-070; 1382-510
i02539434 1. Open the engine compartment.
Cooling System Coolant
Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554;
7542-008; 7542

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. g01272622
Illustration 125

2. The cooling system pressure cap is on the top of

the radiator.

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.

Illustration 124
g01273207 Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
The coolant sample port is located on the left side of cooling system pressure cap is cool enough to
the machine above the alternator. touch with your bare hand.

Obtain the sample of the coolant as close as possible Do not attempt to tighten hose connections when
to the recommended sampling interval. Supplies the coolant is hot, the hose can come off causing
for collecting samples can be obtained from your burns.
Caterpillar dealer.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
KEBU7543-08 99
Maintenance Section
Cooling System Water Temperature Regulator - Replace

3. Remove the cooling system pressure cap slowly

in order to relieve pressure.

4. Inspect the cooling system pressure cap for

foreign material, for deposits, and for damage.
Clean the cooling system pressure cap with a
clean cloth. If the cooling system pressure cap is
damaged, replace the cooling system pressure
cap.

5. Install the cooling system pressure cap.

6. Close the engine compartment.

g01272622
i03303424 Illustration 126

Cooling System Water

Temperature Regulator -
Replace At operating temperature, the engine coolant is
hot and under pressure.
SMCS Code: 1355-510; 1393-010
Steam can cause personal injury.
Replace the water temperature regulator on a regular
basis in order to reduce the chance of unscheduled Check the coolant level only after the engine has
downtime and of problems with the cooling system. been stopped and the fill cap is cool enough to
touch with your bare hand.
The water temperature regulator should be replaced
after the cooling system has been cleaned. Replace Remove the fill cap slowly to relieve pressure.
the water temperature regulator while the cooling
system is completely drained. Replace the water Cooling system conditioner contains alkali. Avoid
temperature regulator while the cooling system contact with the skin and eyes to prevent personal
coolant is drained to a level below the water injury.
temperature regulator housing.
2. Remove the cooling system pressure cap in order
NOTICE to relieve the pressure in the cooling system.
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.

1. Open the engine compartment.

g01272656
Illustration 127

3. Loosen hose clamp (2) and remove hose (3) from

water temperature regulator housing (1).

4. Remove bolts (4) from water temperature

regulator housing (1) and remove water
temperature regulator housing (1).
100 KEBU7543-08
Maintenance Section
Cutting Edges (Leveling Blade) - Inspect/Replace

5. Remove the gasket and remove the water i01735234

temperature regulator from the water temperature
regulator housing. Make a note of the orientation Cutting Edges (Leveling Blade)
of the old regulator. - Inspect/Replace
NOTICE SMCS Code: 6801-040; 6801-510
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. Personal injury or death can result if the levelling
blade is not blocked up. Block the levelling blade
NOTICE before changing the cutting edge.
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.

6. Install a new water temperature regulator. Orient

the regulator in the same manner as the old Illustration 129
g00646073
regulator. Install a new gasket. Install the water
temperature regulator housing. There are two cutting edges on the front of the blade
(1). There are two skid plates on the bottom of the
7. Install the water temperature regulator housing blade (2).
and the hose. Tighten the hose clamp.
Replace the cutting edge if the cutting edge is
damaged. Replace the cutting edge if the cutting
edge is excessively worn.

1. Raise the leveling blade. Block the leveling blade

securely. Place the blocks under the arms (3) of
the blade.

2. Remove the bolts. Remove the cutting edge.

3. Clean the contact surfaces.

4. If the opposite edge of the cutting edge is not

worn, use the opposite edge. If the opposite edge
g01272614 is worn, replace the cutting edge.
Illustration 128

5. Install the bolts. Tighten the bolts to the

8. Add the cooling system coolant. Maintain the level
torques that are specified in the Operation
of the coolant to the top of the radiator and to the
and Maintenance Manual, “Torques for Ground
full line on the expansion tank.
Engaging Tool Bolts”.
9. Inspect cooling system pressure cap and the
6. Inspect the skid plates. Replace the skid plates if
gasket for damage. Replace the pressure cap if
the skid plates are damaged or worn.
the pressure cap or the gasket are damaged.
7. Raise the leveling blade. Remove the blocks.
10. Install the cooling system pressure cap.
8. Lower the leveling blade to the ground.
11. Close the engine compartment.
KEBU7543-08 101
Maintenance Section
Drum Cooling Oil - Change

9. Check the bolts for proper torque after a few hours i01954699
of operation.
Drum Scrapers -
i02527775
Inspect/Adjust/Replace
Drum Cooling Oil - Change SMCS Code: 6607-025; 6607-040; 6607-510

SMCS Code: 6605-044-OC Smooth Drum Scrapers (If

Equipped)
Steel Scrapers
There is one scraper that is located on the front
bumper. There is an optional steel scraper for the
rear of the drum.

Adjust
Loosen the two bolts.

Adjust the steel scraper to 20 mm (0.79 inch) from

Illustration 130
g01264633 the drum surface.

Note: Clean the area around the fill/drain plug before Flexible Scrapers
servicing the drum.

The drum cooling oil requires service when the

disassembly of the drum or the assembly of the drum
is needed.

Rotate the fill/drain plug to the bottom of the drum.

Remove the drain plug. Pump the oil out of the drum.

Use the drain plug opening in order to fill the cavity.

Install the plug after adding the correct amount of oil.
The oil will be near the bottom of the opening.

In order to check the level of the oil, rotate the drum

so the plug is at the bottom of the drum. Remove the
g00930431
plug. Maintain the oil to the bottom of the opening. Illustration 131

Refer to the Operation and Maintenance Manual, Adjust

“Lubricant Viscosities” and the Operation and
Maintenance Manual, “Capacities (Refill)”. 1. Inspect flexible scraper (3). Clean the flexible
scraper of dirt and debris.

2. Loosen bolts (4) that are holding the rear flexible

scraper blade and the backing plate to the bracket.

3. Loosen nuts (1) that hold the front flexible scraper

blade and the backing plate to the bracket.

Note: When you adjust flexible scraper (3), the steel

backing plate (2) must not come into contact with the
surface of the drum.
102 KEBU7543-08
Maintenance Section
Eccentric Weight Housing Oil - Change

4. Adjust flexible scraper blades (3) to 7 mm 2. There are two bolts (2) for each scraper (1). Each
(0.25 inch) away from the surface of the drum. scraper is individually adjustable.
Backing plate (2) must be set back 35 mm
(1.375 inch) from the end of the scraper. Adjust 3. Slide the scraper (1) toward the drum. Adjust
flexible scraper blade (3) and backing plate (2) the tips so the tips are 25 mm (1 inch) from the
together. surface of the drum.

5. Tighten the nuts. 4. Tighten the bolts.

Replace the Flexible Scrapers Bolts (2) .................................. 542 N·m (400 lb ft)

1. Replace the flexible scrapers if excessive wear or i01850129

damage is evident.
Eccentric Weight Housing Oil
2. Loosen the bolts and nuts (1) that are holding
flexible scraper blades (3). - Change
3. Remove the flexible scraper blades (3). Install the SMCS Code: 6606-044-OC
new flexible scraper blades.
Change the Oil
Note: When you adjust flexible scraper blade (3), the
steel backing plate (2) must not come into contact 1. Take an oil sample from each eccentric weight
with the surface of the drum. housing. There is one eccentric weight housing on
each side of the drum. No flushing is necessary, if
4. Adjust the flexible scraper blades (3) to 7 mm the oil sample cleanliness rating is equal or lower
(0.25 inch) away from the surface of the drum. than ISO 23/21. The flushing procedure should
The backing plate (2) must be set back 35 mm be performed if an oil sample cleanliness rating is
(1.375 inch) from the end of the scraper. Adjust higher than ISO 23/21.
the flexible scraper blades (3) and the backing
plate together.

5. Tighten the bolts and tighten the nuts.

Padded Drum Scraper Assembly (If

Equipped)
Adjust

g00946226
Illustration 133
(1) Indicator bar

g00936962
Illustration 132

There is one scraper that is located in front of the

drum. There is a scraper that is located at the rear
of the drum.

1. Inspect the scraper. Clean the dirt and the debris

g00907476
from the scraper. Illustration 134
KEBU7543-08 103
Maintenance Section
Eccentric Weight Housing Oil - Change

2. Rotate the drum until indicator bar (1) is at the top Flush the Housing
of the drum. The drain plug is at the bottom of the
housing.

3. Place a suitable container under the drain

plug. Remove the drain plug. Drain the housing
completely. Repeat this step for both housings.

4. Clean the plug. Install the plug.

5. Rotate the drum until indicator bar (1) is at the

bottom of the drum.

g00661129
Illustration 137

1. There are two eccentric weight housings. The

housings are on each side of the drum. Perform
the following procedure on each housing.

2. Drain the oil from the eccentric weight housings.

g00907477
Illustration 135

6. Remove the filler plug.

g00411939
Illustration 138

3. Pump 151 L (40 US gal) of a suitable hydraulic oil

into a 208 L (55 US gal) drum.

g00907478
Illustration 136

7. Remove the level check plug. Fill the housing

with oil. Refer to the Operation and Maintenance
Manual, “Lubrication Viscosities” and Operation
and Maintenance Manual, “Capacities (Refill)”.
Maintain the level of the oil to the bottom of the
level check opening.

8. Clean the plugs. Install the plugs.

9. Repeat this procedure for the other eccentric

weight housing.
104 KEBU7543-08
Maintenance Section
Eccentric Weight Housing Oil - Change

g00412139
Illustration 141

6. Start the engine. Release the parking brake and

rotate the drum until the fill/drain plug is at the
top of the housing. Remove the plug. Install the
valve and fitting assembly that is appropriate for
g00684344 your machine.
Illustration 139
(1) 8C-6875 Connector
(2) 8B-5774 Reducer Bushing
(3) 9U-6989 Head
(4) 9U-6983 Filter Element
(5) 6V-3965 Nipple Assembly
(6) 8T-4834 Swivel Orifice Tee
(7) 127-8781 Filter Cart
(8) 2.4 m (8 ft) of 25 mm (1 inch) hose
(9) 3B-6498 Elbow
(10) 3L-7024 Street Elbow
(11) 127-0593 Connector
(12) 3B-7728 Elbow
(13) 3B-7265 Pipe Nipple
(14) 940 mm (37 inch) of 25 mm (1 inch) pipe

4. Use the 127-8781 Transfer Cart Group in order

to flush the oil in the 208 L (55 US gal) drum. Filter g00698763
Illustration 142
the oil for 30 minutes. The particle count of the
clean oil must be a maximum of ISO 18/13.
7. Assemble the 126-7187 Adapter (17) into
the male end of the 5R-3796 Quick Coupling
Assembly (16). Install the adapter into the hole
for the oil fill/drain plug. Assemble the 8T-0198
Seal Connector (15) onto the female end of the
quick coupler. Attach the female end of the quick
coupler to the suction hose of the transfer cart in
order to drain the flushing oil from the housing.

g00411939
Illustration 140

5. Raise the machine. The drum and tires must not

be in contact with the ground or the floor. Support
the machine on stands.
KEBU7543-08 105
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace

11. Install the transfer cart. Pump the oil out of the
housings. Cycle the oil through the filter for 30
minutes. Cycle the oil until the oil is cleaned to a
rating of ISO 18/13 or better.

12. Install the transfer cart to the housings. Pump the

oil into the housings. For the second cycle, repeat
steps 6 through 9. After the second cycle, take
an oil sample before filtering the oil. No further
flushing is necessary, if the oil sample cleanliness
rating is equal or lower than ISO 19/16. Another
flushing is necessary, if the oil sample cleanliness
rating is higher than ISO 19/16.

g00907480
13. When the flushing is complete, rotate the drum
Illustration 143 to the position in order to drain the housings.
Remove the valve and fitting assembly. Drain as
8. Rotate the drum until the fill/drain plug is at the much of the oil as possible.
bottom and the indicator bar is at the top.
14. Rotate the drum until the fill/drain plug is at
the top. Remove the level check plug. Fill the
drum to the correct level. Refer to the Operation
and Maintenance Manual, “Capacities (Refill)
”. Refer to the Special Publication, SEBU6250,
“Lubrication Specifications”.

Note: The new oil must have a oil sample cleanliness

rating that is equal or lower than ISO 18/13.

i03631042

Engine Air Filter Primary

Illustration 144
g00412139
Element - Clean/Replace
SMCS Code: 1054-070-PY; 1054-510-PY
9. Remove the level check plug. Connect the quick
coupler (16). Fill the housing with 22 L (6 US gal)
gallons of clean oil. Install the plug. NOTICE
Service the air cleaner only with the engine stopped.
10. Run the first flush cycle. Engine damage could result.

a. Start the engine. Release the brake. Service the air cleaner filter element when the
yellow piston on the engine air filter service
b. Set the travel speed control to low speed. indicator enters the red zone or the indicator
In order to rotate the drum, move the propel reads 63.5 cm (25 inch) of water. Refer to
control. Operation and Maintenance Manual, “Engine Air
Filter Service Indicator - Inspect”.
c. Set the vibratory amplitude control to the low
position. 1. Open the engine compartment.
d. Turn on the vibratory system. Run the vibratory
system for 5 seconds. Turn off the vibratory
system. Repeat the cycle for three minutes.

Note: For each cycle, do not run the vibratory system

more than 5 seconds.

e. Stop the drum. Position the drum in order to

drain the housings.
106 KEBU7543-08
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace

6. Inspect the O-ring seal on the air cleaner cover.

Replace the O-ring seal if the O-ring seal is worn
or damaged.

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.
g00537958
Illustration 145
7. Clean the primary filter. Inspect the primary filter.
2. Squeeze the outlet tube slightly in order to purge
the dirt from the outlet tube. Primary filter elements can be cleaned with low
pressure air. Caterpillar does not recommend
cleaning the air filter.

Refer to Operation and Maintenance, “General

Hazard Information” before you use pressure air
in order to clean the primary filter element.

g00101413
Illustration 146

3. Loosen the four cover latches and remove the air

cleaner cover.

g00102970
Illustration 148

8. Direct air along the pleats inside the primary filter

element and outside the primary filter element. Do
not touch pleats with the air nozzle.

9. Inspect the primary filter element after the element

is clean. Do not use a primary filter element with
damaged pleats, damaged gaskets or damaged
seals.

10. Encase the clean primary filter element and store

Illustration 147
g00101415 the clean primary filter element in a clean, dry
place.
4. Remove the primary filter element from the air
cleaner housing. 11. Install the clean primary filter.

5. Clean the air cleaner cover and the inside of the 12. Install the air cleaner cover and close the latches
air cleaner housing. securely.
KEBU7543-08 107
Maintenance Section
Engine Air Filter Secondary Element - Replace

g00101416 g00101451
Illustration 149 Illustration 150

Note: Install the air cleaner cover properly. The 3. Remove the secondary filter element.
arrows must point upward.
4. Cover the air inlet opening. Clean the inside of
13. Change the filter if the exhaust smoke is still the air cleaner housing.
black.
5. Remove the cover from the air inlet opening.
Note: Replace the primary filter if the primary filter
has been in service for one year. 6. Install the new secondary filter element.

14. Close the engine compartment. 7. Install the primary filter element.

8. Install the air cleaner cover and close the latches

i03631053
securely.
Engine Air Filter Secondary 9. Close the engine compartment.
Element - Replace
SMCS Code: 1054-510-SE i02539450

Engine Air Filter Service

NOTICE
Always replace the secondary filter element. Never at- Indicator - Inspect
tempt to reuse the secondary filter element by clean-
ing the element. SMCS Code: 7452-040

When the primary filter element is replaced, the sec- 1. Open the engine compartment.
ondary filter element should be replaced.
Note: The engine air filter service indicator will stay
The secondary filter element should also be replaced at the maximum reading until the engine air filter
if the exhaust smoke is still black. service indicator is reset.

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.

g01272766
Illustration 151
108 KEBU7543-08
Maintenance Section
Engine Oil Level - Check

2. If the yellow piston in the engine air filter service

indicator enters the red zone, service the air NOTICE
cleaner. Do not overfill the crankcase. The oil level must not
reach the top of the FULL range mark or above the
Note: See the Operation and Maintenance Manual, FULL range mark.
“Engine Air Filter Primary Element - Clean/Replace”.
See the Operation and Maintenance Manual, “Engine
Air Filter Secondary Element - Replace”. 3. Maintain the oil level on the oil level gauge
between the FULL RANGE mark and the ADD
3. Close the engine compartment. OIL mark . Add oil if the oil level is too low.

Note: Operating your engine with the oil level above

i02539468 the FULL mark in the FULL Range could cause
the crankshaft to dip into the oil. This could result
Engine Oil Level - Check in excessively high operating temperatures. The
high operating temperatures could result in reduced
SMCS Code: 1348-535-FLV lubricating characteristics of the oil. This could cause
damage to the bearings and loss of engine power.
NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage. Add The Engine Oil
1. Open the engine compartment.
Stop the engine in order to check the oil level. DO
NOT check the oil level when the engine is running.

Park the machine on a level surface.

1. Open the engine compartment.

g01405196
Illustration 153

2. Remove oil filler plug (2).

3. Add the oil.

g01273185
Illustration 152 4. Clean the oil filler plug. Install the oil filler plug.

2. Remove oil level gauge (1). Wipe the oil level 5. Close the engine compartment.
gauge with a clean cloth. Insert the oil level gauge.
Remove the oil level gauge and note the oil level.
i02539470
Insert the oil level gauge.

Note: Refer to the Operation and Maintenance

Engine Oil Sample - Obtain
Manual, “Lubricant Viscosities and Capacities (Refill)” SMCS Code: 1000-008
for the correct amount of oil that is used when the
oil is changed. The correct amount of oil determines
the correct level of the oil in the FULL range on the
oil level gauge.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
KEBU7543-08 109
Maintenance Section
Engine Oil and Filter - Change

Obtain the Sample and the Analysis i02539471

In addition to a good preventive maintenance Engine Oil and Filter - Change

program, Caterpillar recommends using S·O·S oil
analysis at regular scheduled intervals in order SMCS Code: 1318-510
to monitor the condition of the engine and the
maintenance requirements of the engine. Run the engine in order to warm up the oil. Stop
the engine before you drain the oil. When the oil is
Each oil sample should be taken when the oil is warm warm the waste particles are suspended in the oil.
and when the oil is well mixed. The sample should be The waste particles will be removed when the oil is
taken at this time in order to ensure that the sample drained.
is representative of the oil in the crankcase.
As the oil cools, the waste particles settle to the
bottom of the oil pan. The waste particles will not be
Obtain the S·O·S Sample removed if the oil is too cool.
Use the oil sampling valve in order to obtain an S·O·S The waste particles can recirculate through the
sample. engine lubrication system if the recommended
procedure is not followed.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil 1. Open the engine compartment.
samples must be clean.

Refer to Special Publication, PEHP6001 for more

information on obtaining a good oil sample. Consult
your Caterpillar dealer for complete information and
assistance in establishing an S·O·S program for your
engine.

1. Open the engine compartment.

g01273193
Illustration 155

2. Place a suitable container under the drain valve.

Refer to the Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.

3. Remove the oil drain tube from the storage

g01272930 location in the pouch on the back of the seat. The
Illustration 154 drain tube includes an O-ring fitting and a valve.
2. The oil sampling valve is on the right side of the 4. Push the O-ring fitting into the oil drain port on the
machine. The oil sampling valve is located above engine. Orient the drain tube so the oil will drain
the oil filter. into the container.
3. Open the sampling valve. Obtain an oil sample in 5. Open the valve on the drain tube in order to drain
a suitable container and close the sampling valve. the oil.
Refer to the Operation and Maintenance Manual,
“General Hazard Information” for information that 6. Allow the oil to completely drain.
pertains to containing fluid spillage.
7. Close the drain valve and remove the drain tube
4. Seal the container and label the container. Send from the drain port.
the sample to your Caterpillar dealer for analysis.
8. Clean the drain tube of oil and return the drain tube
5. Close the engine compartment. to the storage location on the back of the seat.
110 KEBU7543-08
Maintenance Section
Engine Valve Lash - Check/Adjust

15. Start the engine. Run the engine for two minutes.
Inspect the machine for leaks. Stop the machine.

16. Wait for ten minutes in order to allow the oil to

drain back into the crankcase. Check the oil level.
Maintain the oil level within the FULL RANGE on
the dipstick.

17. Close the engine compartment.

i03363188

Engine Valve Lash -

g01273195
Check/Adjust
Illustration 156
SMCS Code: 1105-025; 1105-535
9. Remove filter element (1). Discard the used filter
element. This maintenance is recommended by Caterpillar
as part of a lubrication and preventive maintenance
10. Clean the filter housing base. All of the old filter schedule in order to help provide maximum engine
seal must be removed from the filter housing base. life.

11. Apply a thin coat of engine oil to the seal of the

new filter elements.
Ensure that the engine can not be started while
12. Install the new filters by hand. When the seal
this maintenance is being performed. To help pre-
contacts the base, tighten the filter element for
an additional 3/4 turn. This will tighten the filter vent possible injury, do not use the starting motor
to turn the flywheel.
sufficiently.

Every new oil filter has rotation index marks that Hot engine components can cause burns. Allow
additional time for the engine to cool before mea-
are spaced at 90 degree increments. Use the
suring/adjusting valve lash clearance.
rotation index marks as a guide for tightening the
oil filter.
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.

Note: Any air lines that are disconnected during a

valve lash adjustment must be plugged in order to
protect the engine. Prevent the entry of airborne dirt,
g01405196
Illustration 157 debris and abrasive particles. Keep all parts clean
from contamination. Contaminants may cause rapid
13. Remove the oil filler plug. Fill the crankcase wear. This shortens the component life.
with new oil. See Operation and Maintenance
Manual, “Capacities (Refill)”. See Operation and
Maintenance Manual, “Lubricant Viscosities”.
Clean the oil filler cap and install the oil filler cap.

14. Before you start the engine, check the oil level on
the dipstick. The oil level must be within the FULL
RANGE on the dipstick.
KEBU7543-08 111
Maintenance Section
Final Drive Planetary (Axle) Oil - Change

i02797878 11. Apply the parking brake.

Final Drive Planetary (Axle) Oil 12. Stop the engine. Check the oil level.
- Change 13. Check the drained oil for metal chips or for
SMCS Code: 4050-044-OC particles. If there are any chips or particles, consult
your Caterpillar dealer.

14. Properly dispose of the drained material. Obey

local regulations for the disposal of the material.

i02797914

Final Drive Planetary (Axle) Oil

Level - Check
SMCS Code: 4050-535-FLV

g01397975
Illustration 158

1. Position one final drive so that the oil fill/drain plug

is at the bottom.

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information on
Containing Fluid Spillage.

2. Remove the oil fill/drain plug. Allow the oil to drain

into a suitable container.
g01397999
3. Clean the plug and inspect the O-ring seal. If wear Illustration 159
or damage is evident, replace the oil fill/drain plug
and/or the O-ring seal. 1. Position the machine so that the oil fill/drain plug
is horizontal.
4. Install the oil fill/drain plug.
Note: Refer to Operation and Maintenance Manual,
5. Rotate the final drive so that the oil fill/drain plug is “General Hazard Information” for information on
horizontal. Containing Fluid Spillage.

6. Fill the final drive to the bottom of the opening 2. Remove the oil fill/drain plug.
on the oil fill/drain plug. See Operation and
Maintenance Manual, “Lubricant Viscosities” and 3. Check the oil level. The oil should be near the
Operation and Maintenance Manual, “Capacities bottom of the oil fill/drain plug.
(Refill)”.
4. Add oil through the oil fill/drain plug, if necessary.
7. Install the oil fill/drain plug.
Note: Do not overfill the final drive.
8. Perform Step 1 to Step 7 on the other final drive.
Use a different container for the oil so that the oil 5. Clean the oil fill/drain plug. Inspect the O-ring seal.
samples from the final drives will be separate. Replace the O-ring seal if the O-ring seal is worn
or damaged.
9. Completely remove the oil that has spilled onto
surfaces. 6. Install the oil fill/drain plug.

10. Start the engine. Operate the machine in the 7. Repeat the procedure for the other final drive.
FORWARD direction and in the REVERSE
direction.
112 KEBU7543-08
Maintenance Section
Final Drive Planetary (Axle) Oil Sample - Obtain

i02797921 Procedure
Final Drive Planetary (Axle) Oil
Sample - Obtain
SMCS Code: 4050-008

g01269069
Illustration 161

The final drive planetary is located on the left side

of the drum.

g01397999
Illustration 160

Obtain the oil sample when you change the oil.

Refer to the Operation and Maintenance Manual,

“General Hazard Information” for information that
pertains to fluid spillage.

Refer to the Special Publication, SEBU6250, “S·O·S

Oil Analysis”.

i04286241

Final Drive Planetary (Drum) Illustration 162

g01269073

Oil - Change 1. Drain plug (3) is located at the bottom of the final
SMCS Code: 4050-044-OC; 5655-044-OC drive planetary.

2. Remove drain plug (3). Drain the oil into a suitable

Maintenance Interval container. Dispose of the oil in an acceptable
manner. Refer to the Operation and Maintenance
The standard maintenance interval for changing the Manual, “General Hazard Information” for
final drive planetary (drum) oil is every 1000 service information that pertains to containing fluid
hours or 1 year when using ISO 220 or ISO 68 oil. If spillage.
Cat TDTO or commercial TO-4 oil is used, then the
interval must be changed to every 500 service hours 3. Inspect drain plug (3) for metal debris. If the size
or 6 months. of the metal debris is 3 mm (0.12 inch) or more,
there may be damage to the planetary.

Note: Consult your Caterpillar dealer for further

information.

4. After the oil is drained, install drain plug (3).

KEBU7543-08 113
Maintenance Section
Final Drive Planetary (Drum) Oil - Check

g01269081 g01269081
Illustration 163 Illustration 165

5. Filler plug (1) is located at the top of the planetary 1. Remove level check plug (2). Check the level of
and level check plug (2) is located at the middle. the oil in the planetary. Maintain the level of the oil
at the bottom of the opening for level check plug
6. Remove level check plug (2) and filler plug (1). (2).

7. Refer to the Operation and Maintenance Manual, 2. Clean plug(2). Install plug (2).
“Lubricant Viscosities and Capacities (Refill)”.
i02535805
8. Fill the planetary until the oil is at the bottom of
level check plug (2). Final Drive Planetary (Drum)
Note: Check the oil again after 5 minutes. This Oil Sample - Obtain
allows time for the oil to travel through the planetary.
Continue to fill and wait until the oil level remains at SMCS Code: 4050-008; 5655-008
the bottom of level check plug (2).

9. Clean plugs (1) and (2). Install plugs (1) and (2).

i02535743

Final Drive Planetary (Drum)

Oil - Check
SMCS Code: 4050-535-FLV; 5655-535-FLV

g01269102
Illustration 166

Obtain the oil sample according to the Operation

and Maintenance Manual, “Maintenance Interval
Schedule”.

Refer to the Operation and Maintenance Manual,

“General Hazard Information” for information that
pertains to containing fluid spillage.

Refer to the Special Publication, SEBU6250, “S·O·S

g01269069
Illustration 164 Oil Analysis” for more information.

The final drive planetary is located on the left side

of the drum.
114 KEBU7543-08
Maintenance Section
Fuel System - Prime

i02539480

Fuel System - Prime

SMCS Code: 1250-548

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol-
low these inspection, maintenance and service in-
structions may cause personal injury or death.

g01410726
Refer to the Operation and Maintenance Manual , Illustration 167
“General Hazard Information and High Pressure Fuel
Lines” before adjustments and repairs are performed. 1. Move the switch for the electric fuel priming pump
to the ON position. Allow the pump to run for
Note: Refer to Testing and Adjusting Manual several seconds.
, “Cleanliness of Fuel System Components”
for detailed information on the standards of 2. Return the switch for the electric fuel priming
cleanliness that must be observed during ALL pump to the OFF position.
work on the fuel system.
3. Start the engine. If the engine does not start,
Ensure that all adjustments and repairs are performed or if the engine continues to misfire or smoke,
by authorized personnel that have had the correct additional priming may be necessary. The electric
training. fuel priming pump will only operate if the engine
start switch key is in the OFF position. Shut off the
NOTICE engine before additional priming.
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two 4. Run the engine at the LOW IDLE position until the
minutes before cranking the engine again. engine runs smoothly.

i02827693
If air enters the fuel system, the air must be purged
from the fuel system before the engine can be
started. Air can enter the fuel system when the
Fuel System Primary Filter
following events occur: (Water Separator) - Replace
• The fuel tank is empty or the fuel tank has been SMCS Code: 1261-510; 1263-510
partially drained.

• The low pressure fuel lines are disconnected.

Personal injury can result from air pressure.
• A leak exists in the low pressure fuel system.
Personal injury can result without following prop-
• The fuel filter has been replaced. er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Electric Fuel Priming Pump
Maximum air pressure at the nozzle must be less
This machine is equipped with an electric fuel priming than 205 kPa (30 psi) for cleaning purposes.
pump.

Note: You can only use the priming pump when

the engine start switch key is OFF.
KEBU7543-08 115
Maintenance Section
Fuel System Primary Filter (Water Separator) - Replace

• Regularly clean the outside of the fuel filler cap

and the area around the fuel filler cap.
Personal injury can result when using cleaner sol-
vents. • Only use Caterpillar approved fuel filters. The
use of Caterpillar filters is essential in order to
protect the fuel system.
To help prevent personal injury, follow the instruc-
tions and warnings on the cleaner solvent contain-
er before using. • Do not service the fuel filters ahead of the
suggested maintenance interval, unless you
are instructed by the monitoring system. This
will increase the risk of contamination in the
fuel system.
Personal injury or death can result from a fire.
Note: In order to reduce the risk of contamination in
the system, do not remove the primary fuel filter and
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. the secondary fuel filters simultaneously. Perform
these operations separately.
Clean up all leaked or spilled fuel. Do not smoke
while working on the fuel system. Note: After the engine has stopped, you must
wait for 60 seconds in order to allow the fuel
pressure to be purged from the high pressure fuel
Turn the disconnect switch OFF or disconnect the
battery when changing fuel filters. lines before any service or repair is performed
on the engine fuel lines.

NOTICE 1. Open the engine compartment. The fuel filter

Do not pre-fill the fuel filter with fuel before you install element is located on the right side of the machine
the fuel filter. Contaminated fuel WILL DAMAGE the toward the rear of the engine compartment.
fuel system components.
2. Turn the fuel supply valve (if equipped) to the OFF
position before performing this maintenance.
NOTICE
Caterpillar STRONGLY recommends the use of ad- 3. Place a suitable container under the water
vanced efficiency (high efficiency) primary fuel fil- separator in order to catch any fuel that might spill.
ters. Advanced efficiency fuel filters are designed Clean up any spilled fuel. Clean the outside of the
in order to better protect diesel engines that have water separator and the fuel filter.
higher injection pressures and closer tolerances.
Use of primary fuel filters that are NOT advanced
efficiency fuel filters will result in shortened fuel
system component life. Caterpillar advanced effi-
ciency fuel filters are the preferred primary filters
for Caterpillar engines.

NOTICE
Severe working conditions can shorten the life of the
fuel system. Severe conditions refer to a dusty envi-
ronment and/or dirty fuel. Under severe conditions, re-
duce the maintenance interval to 250 service hours.

In order to keep the engine in optimum condition, it is g01306245

Illustration 168
important to keep the fuel free from contamination.
As fuel system contamination usually occurs during
refueling, the following points should be observed: 4. Open the drain (3). Allow the fluid to drain into
the container.
• Only use clean fuel of the correct grade from 5. Tighten the drain by hand pressure only.
a reliable source.
6. If equipped, remove the wiring harness from the
• Do not refuel from contaminated containers or sensor on the bottom of the clear bowl (2).
containers that are not suitable for fuel storage.
7. Remove the clear bowl from the filter (1).
• Do not use contaminated equipment.
116 KEBU7543-08
Maintenance Section
Fuel System Secondary Filter - Replace

8. Use a Caterpillar strap wrench in order to remove i02818340

the filter. Discard the old seals and the canister in
a safe place. Fuel System Secondary Filter -
9. Clean the clear bowl.
Replace
SMCS Code: 1261-510-SE
10. Install a new filter.

Note: Do not pre-fill the fuel filter before you

install the fuel filter.
Personal injury can result from air pressure.
a. Install a new filter hand tight until the seal of
the filter contacts the base. Note the position Personal injury can result without following prop-
of the index marks on the filter in relation to a er procedure. When using pressure air, wear a pro-
fixed point on the filter base. tective face shield and protective clothing.

Note: There are rotation index marks on the filter Maximum air pressure at the nozzle must be less
that are spaced 90 degrees or 1/4 of a turn away than 205 kPa (30 psi) for cleaning purposes.
from each other. When you tighten the filter, use the
rotation index marks as a guide.

b. Tighten the filter according to the instructions

that are printed on the filter. Use the index Personal injury can result when using cleaner sol-
marks as a guide. vents.

11. Install the clear bowl on the filter. Ensure that the To help prevent personal injury, follow the instruc-
sensor (if equipped) is in the correct position. tions and warnings on the cleaner solvent contain-
er before using.
12. If equipped, install the wiring harness to the
sensor.

13. Be sure to dispose of the fuel in a safe place.

Personal injury or death can result from a fire.
14. Prime the fuel system. Refer to Operation and
Maintenance Manual, “Fuel System - Prime” for Fuel leaked or spilled onto hot surfaces or electri-
more information. cal components can cause a fire.

15. Close the engine compartment. Clean up all leaked or spilled fuel. Do not smoke
while working on the fuel system.

Replace the Secondary Fuel Filter Turn the disconnect switch OFF or disconnect the
battery when changing fuel filters.
Replace the secondary fuel filter immediately after
you change the primary fuel filter. Refer to Operation
and Maintenance Manual, “Fuel System Secondary NOTICE
Filter - Replace”for more information. Do not pre-fill the fuel filter with fuel before you install
the fuel filter. Contaminated fuel WILL DAMAGE the
fuel system components.

NOTICE
Caterpillar STRONGLY recommends the use of
ultra-high efficiency secondary fuel filters for this
machine model. Ultra-high efficiency fuel filters
are designed in order to better protect diesel
engines that have higher injection pressures and
closer tolerances. Use of secondary fuel filters
that are NOT ultra-high efficiency fuel filters will
result in shortened fuel system component life.
Caterpillar ultra-high efficiency fuel filters are
the preferred secondary filters for this machine
model.
KEBU7543-08 117
Maintenance Section
Fuel Tank Cap and Strainer - Clean

NOTICE
Severe working conditions can shorten the life of the
fuel system. Severe conditions refer to a dusty envi-
ronment and/or dirty fuel. Under severe conditions, re-
duce the maintenance interval to 250 service hours.

In order to keep the engine in optimum condition, it is

important to keep the fuel free from contamination.
As fuel system contamination usually occurs during
refueling, the following points should be observed:

• Only use clean fuel of the correct grade from

a reliable source.
g01273157
Illustration 169
• Do not refuel from contaminated containers or
containers that are not suitable for fuel storage. 3. Clean the outside of the fuel filter. Use a Caterpillar
strap wrench in order to remove the filter from the
• Do not use contaminated equipment. engine and dispose of the filter in a safe place.

• Regularly clean the outside of the fuel filler cap 4. Install a new filter.
and the area around the fuel filler cap.
Note: Do not pre-fill the new filter before you
• Only use Caterpillar approved fuel filters. The install the new filter.
use of Caterpillar filters is essential in order to
protect the fuel system. a. Install a new filter hand tight until the seal of
the filter contacts the base. Note the position
• Do not service the fuel filters prior to the of the index marks on the filter in relation to a
suggested maintenance interval. This may fixed point on the filter base.
increase the risk of contamination in the fuel
system. Note: There are rotation index marks on the filter
that are 90 degrees or 1/4 of a turn away from each
Note: In order to reduce the risk of contamination other. When you tighten the filter, use the rotation
in the system, do not remove the primary fuel filter index marks as a guide.
and the secondary fuel filter simultaneously. Perform
these operations separately. b. Tighten the filter according to the instructions
that are printed on the filter. Use the index
Note: After the engine has stopped, you must marks as a guide.
wait for 60 seconds in order to allow the fuel
pressure to be purged from the high pressure fuel 5. Prime the fuel system. Refer to the Operation and
lines before any service or repair is performed Maintenance Manual, “Fuel System - Prime” for
on the engine fuel lines. more information.

1. Open the engine compartment. The secondary 6. Before you start the engine, make sure that the
fuel filter is located on the right side of the machine drain valves are completely closed. Start the
toward the rear of the engine compartment. engine. Check for leaks.

2. Ensure that the fuel supply valve (if equipped) is in 7. Close the engine compartment.
the OFF position. Place a suitable container under
the fuel filter in order to catch any fuel that might
spill. Clean up any spilled fuel. i04291810

Fuel Tank Cap and Strainer -

Clean
SMCS Code: 1273-070-Z2; 1273-070-STR

1. The fuel tank is located on the rear of the machine

under the enclosure. Open the engine enclosure
to access the fuel tank.
118 KEBU7543-08
Maintenance Section
Fuel Tank Water and Sediment - Drain

g02458361 g02460331
Illustration 170 Illustration 172

2. Lift lever (2) and turn the lever counterclockwise 10. Inspect seal (5) for damage. Replace the seal if
until the lever stops. Remove fuel cap (1). damaged or worn.

3. Remove fuel strainer (3). 11. Put a light coat of fuel on the fuel cap seal.

4. Seal the tank in order to prevent contamination. 12. Wash the fuel strainer (3) in a clean,
nonflammable solvent.

13. Install fuel strainer (3).

14. Install fuel cap (1). Turn lever (2) clockwise until
the lever stops. Fold lever (2) down.

i02539484

Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543-M&S
g02460326
Illustration 171

5. Turn over fuel cap (1).

6. Remove filter cover (4) by separating the cover

from the fuel cap. Remove the filter.

7. Wash the cap and filter in a clean, nonflammable

solvent.

8. Inspect the filter elements of the fuel cap. Replace

the filter elements if damaged or worn.

9. Install the filters and filter cover (4). g01272902

Illustration 173

The drain valve is located on the bottom of the fuel

tank.

Drain the water and the sediment into a suitable

container. Refer to the Operation and Maintenance
Manual, “General Hazard Information” for information
that pertains to containing fluid spillage.
KEBU7543-08 119
Maintenance Section
Fuses - Replace

Close the drain valve. Install the access plate. In order to access the compartment for the fuses,
remove the four screws. Remove the cover.
Note: Dispose of all fluids according to local
regulations. Engine Preheater (1) – 15 amp

i03631056

Fuses - Replace Hazard Lights (2) – 10 amp

SMCS Code: 1417-510

Fuse – The fuses protect the electrical Backup Alarm (3) – 10 amp
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 machine. Vital Information Management System
(4) – 15 amp

Ignition System (5) – 10 amp

Front Work Lights (6) – 10 amp

Horn (7) – 10 amp

g00999195
Illustration 174
Gauge Lights (8) – 10 amp

Ventilation System (9) – 10 amp

Spare Fuse (10) – 10 amp

Vibratory System (11) – 10 amp

Spare Fuse (12) – 15 amp

Illustration 175
g01260619 Window Wiper/Washer (13) – 10 amp

The compartment for the fuses is located on the right

side of the operator station. There are four screws
that hold the cover on the compartment. Rear Work Lights (14) – 10 amp
120 KEBU7543-08
Maintenance Section
Hydraulic System Oil - Change

Electronic Control Module (15) – 5 amp

Parking Brake (16) – 10 amp

i03631059

Hydraulic System Oil - Change

SMCS Code: 5050-044; 5095-044
g01272821
Illustration 176

Cat HYDO Oil Change Interval 1. Remove the hydraulic tank cap.
The standard Cat HYDO oil change interval is every
2. Wash the hydraulic tank cap in clean,
2000 service hours or 1 year.
nonflammable solvent.
A 4000 service hour or 2 year maintenance interval
for hydraulic oil (change) is available. The extended
interval requires S·O·S monitoring of the hydraulic
oil. The interval for S·O·S monitoring is every 500
hours. The maintenance interval for the hydraulic oil
filter is not changed.

Cat HYDO Advanced 10 Oil Change

Interval
The standard Cat HYDO Advanced 10 oil change
interval is every 3000 service hours or 18 months.

A 6000 service hour or 3 year maintenance interval Illustration 177

g01272895
for hydraulic oil (change) is available. The extended
interval requires S·O·S monitoring of the hydraulic 3. The drain valve is located on the bottom of the
oil. The interval for S·O·S monitoring is every 500 hydraulic oil tank. The drain valve is opened by
hours. The maintenance interval for the hydraulic oil attaching the drain hose that is shipped with the
filter is not changed. machine. Drain the fluid into a suitable container.

Procedure to Change the Hydraulic Note: Dispose of the used oil in a proper manner.
Refer to the Operation and Maintenance Manual,
Oil “General Hazard Information” for information that
pertains to containing fluid spillage.
NOTICE
Take extreme care to insure the cleanliness of the hy- 4. Close the hydraulic oil tank valve by removing the
draulic oil. Keep the hydraulic oil clean in order to ex- hose.
tend the component life and assure the maximum per-
formance. 5. Refill the hydraulic tank with clean, filtered
hydraulic oil. Refer to the Operation and
Maintenance Manual, “ Capacities (Refill) and
Lubricant Viscosities”.

6. Add the oil through the filler tube.

KEBU7543-08 121
Maintenance Section
Hydraulic System Oil Filter - Replace

2. In order to catch any oil that spills, place a suitable

container under the filters.

3. Remove the two filter elements. Clean the filter

bases. Discard the filters in a proper manner.
Refer to the Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to fluid spillage.

4. Coat the gaskets of new filters with clean oil.

5. Install the new filter elements. Hand tighten the

elements. When the gasket contacts the filter
base, tighten the filter element for an additional
g01272877
3/4 turn. This will tighten the filter sufficiently. The
Illustration 178 filters have index marks that are spaced at 90
degree intervals.
7. Maintain the oil level within the top sight glass.
When the oil is at ambient temperature the oil
should be just visible within the bottom of the
top sight glass. When the oil is at operating
temperature the top sight glass should be half full.

i03326884

Hydraulic System Oil Filter -

Replace
SMCS Code: 5068-510

Replace the hydraulic system oil filter every 1000

service hours or 1 year. If S·O·S analysis is performed Illustration 180
g01272877
then the hydraulic system oil filter can be replaced
every 2000 service hours or 2 years. 6. Start the engine. Allow the hydraulic oil to warm.
Maintain the oil level within the top sight glass.
NOTICE When the oil is at ambient temperature the oil
Take extreme care to insure the cleanliness of the hy- should be just visible within the bottom of the
draulic oil. Keep the hydraulic oil clean in order to ex- top sight glass. When the oil is at operating
tend the component life and assure the maximum per- temperature the level should be halfway up the
formance. top sight glass. If necessary, add oil.

Refer to the Operation and Maintenance Manual,

“Capacities (Refill)”. Refer to the Operation and
Maintenance Manual, “Lubricant Viscosities”.

i03327743

Hydraulic System Oil Level -

Check
SMCS Code: 5056-535-FLV; 5095-535-FLV

Note: Always check the hydraulic oil level when the

machine is parked on a level surface.
g01272887
Illustration 179

1. There are two filters. The filters are on the left

side of the machine. The filters are located behind
the steps.
122 KEBU7543-08
Maintenance Section
Hydraulic System Oil Sample - Obtain

i02539499

Hydraulic System Oil Sample

- Obtain
SMCS Code: 5050-008; 5056-008; 5095-008

g01272877
Illustration 181

1. Observe the level of the hydraulic oil in the sight

glasses. Maintain the oil level within the top sight
glass. When the oil is at ambient temperature
the oil should be just visible within the bottom of
the top sight glass. When the oil is at operating Illustration 183
g01272831
temperature the top sight glass should be half full.
The sampling port for the hydraulic oil is located
2. If necessary, add oil. next to the hydraulic oil filters. Refer to the Special
Publication, SEBU6250, “Caterpillar Machine Fluids
Refer to the Operation and Maintenance Manual, Recommendations” for further information on
“Capacities (Refill)”. Refer to the Operation and obtaining oil samples.
Maintenance Manual, “Lubricant Viscosities”.

i02539501

Hydraulic Tank Breather -

Replace
SMCS Code: 5050-510-BRE; 5056-510-BRE;
5118-510

g01272821
Illustration 182

3. In order to add the oil, remove the filler cap. Add

the oil through the filler tube. Clean the oil filler
cap and install the filler cap.

g01272943
Illustration 184

1. Open the engine compartment.

2. Remove the breather.

3. Replace the breather.

4. Close the engine compartment.

KEBU7543-08 123
Maintenance Section
Indicators and Gauges - Test

i01829877 4. Turn on all machine lights. Check for proper

operation.
Indicators and Gauges - Test
5. Stop the engine.
SMCS Code: 7450-081
Note: When the engine is stopped and the engine
start switch key is turned to the ON position, all of
the indicator lights should illuminate. If the indicator
lights do not illuminate, repair the lights or replace
the lights.

6. Make any repairs that are required before

operating the machine.

i03174984

Isolation Mounts -
Inspect/Replace
g00934023
Illustration 185
SMCS Code: 5654-040; 5654-510

g00934022
Illustration 186 g01265753
Illustration 188

Inspect the isolation mounts for cracks which exceed

25 mm (1 inch). If any mount is found with a crack
that exceeds 25 mm (1 inch) then replace all of the
mounts on that side of the machine.

Check the machine for broken mounts. If any mounts

are completely broken through then replace all of the
mounts on that side of the machine.

Check for a split in the middle of the mounts. If any of

the mounts are split in the middle then replace all of
the mounts on that side of the machine.
g00889941
Illustration 187
i03754815

1. Look for broken lenses on the gauges, broken Leveling Blade - Lubricate
indicator lights, broken switches, and other broken
components in the cab. (If Equipped)
2. Start the engine. SMCS Code: 5102-086; 5103-086; 6060-086

3. Look for inoperative gauges. Note: Clean the fittings before you lubricate the
fittings.
124 KEBU7543-08
Maintenance Section
Neutral Start Switch - Test

g00889952 g00934061
Illustration 189 Illustration 191

Lubricate the grease fitting that is located at the top 1. Place the propel lever in the FORWARD position.
of the leveling blade cylinder.

g01265736
Illustration 192
g02025212
Illustration 190
2. Hold the engine start switch in the START position.
Lubricate grease fitting (1) that is located at the Slowly move the propel lever toward the STOP
bottom of the leveling blade cylinder. position.

There are two grease fittings (2) for the blade pivot 3. If the engine starts before you move the propel
pins that must be lubricated. The fittings are located lever to the STOP position, the neutral start switch
at the bottom of the pivot. There is one fitting on each requires adjustment. Do not operate the machine
side of the machine. until the repairs have been made. Consult your
Caterpillar dealer for instructions.
i02529538

Neutral Start Switch - Test

SMCS Code: 1424-025; 1424-081; 1424-535

The machine may lurch forward if the neutral start

switch is out of adjustment. Be sure the area is
clear of all personnel and equipment before per-
forming this test.
KEBU7543-08 125
Maintenance Section
Oil Filter - Inspect

i02106227 i02828679

Oil Filter - Inspect Parking Brake - Check

SMCS Code: 1308-507; 3004-507; 3067-507; SMCS Code: 4267-535
5068-507
Note: If the machine configuration changes, the
parking brakes need to be tested.
Inspect a Used Filter for Debris
Check the area around the machine. Make sure
that the machine is clear of personnel and clear of
obstacles.

Put the steering frame lock in the UNLOCKED

position.

Fasten the seat belt before checking the parking

brake.

The following tests are used 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
Illustration 193
g00100013 all of the steps before you perform the following
procedure.
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 metals.

Ferrous metals can indicate wear on steel parts and

on cast iron parts.

Nonferrous metals can indicate wear on the Illustration 194

g01410997
aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings. Position the machine on the incline of the slope, but
near the base of the slope in order to check the
Small amounts of debris may be found in the filter parking brake. The test position should be 40 percent
element. This could be caused by friction and by or a 22 degree slope.
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount 1. Start the engine. Refer to the Operation and
of debris is found. Maintenance Manual, “Engine Starting” for
information on starting the engine.
Using an oil filter element that is not recommended
by Caterpillar can result in severe engine damage 2. If your machine is equipped with a leveling blade,
to engine bearings, to the crankshaft, and to other raise the leveling blade. Move the machine into
parts. This can result in larger particles in unfiltered the test position.
oil. The particles could enter the lubricating system
and the particles could cause damage. 3. Place the throttle control into the LOW IDLE
position.

4. Engage the parking brake.

The machine should not move under the following

conditions.
126 KEBU7543-08
Maintenance Section
Propel Control Tension - Adjust

• The engine is at low idle.

• The propel lever is in the NEUTRAL position.
• The parking brake is engaged.
• The machine is positioned on the specified
slope.

Personal injury can result if the machine moves

while testing.

If the machine begins to move, release the parking Illustration 195

g01344379
brake and use the propel lever in order to move the (1) Bolts
machine to a level surface. (2) Cover

5. Park the machine on a level surface. If your 5. Remove bolts (1) and console cover (2) in order to
machine is equipped with a leveling blade, lower access the tensioner for the control lever.
the leveling blade to the ground.

6. Stop the engine.

NOTICE
If the machine moved during the brake test, consult
your Caterpillar dealer.

The dealer must inspect the brake system and make

any necessary repairs before the machine is returned
to operation.

i02798001

Propel Control Tension -

Adjust
SMCS Code: 3209-025
g01343919
1. Park the machine on a flat, level surface. Illustration 196
(3) Lever
2. Apply the parking brake. (4) Jam nut
(5) Locknut
3. Place the keyswitch in the OFF position.

4. Locate the propel lever on the operator station.

KEBU7543-08 127
Maintenance Section
Radiator Core - Clean

g01343906 g00101939
Illustration 197 Illustration 199
(4) Jam nut
(5) Locknut Inspect the radiator core for debris. If necessary,
clean the radiator.
6. Loosen jam nut (4).
Compressed air is preferred, but high pressure water
7. Tighten locknut (5) until a force of 24 ± 2 N or steam can be used to remove dust and general
(5.5 ± .5 lb) is needed to move lever (3). debris from a radiator. Clean the radiator according
to the condition of the radiator.
8. Tighten jam nut (4) to a torque of 11 N·m
(100 lb in). Note: High pressure water can bend the oil cooler
and the radiator fins.

See Special Publication, SEBD0518, “Know Your

Cooling System” for more information about cleaning
radiator fins.

Close the engine compartment.

i02529471

Rollover Protective Structure

(ROPS) - Inspect
SMCS Code: 7323-040
g01344379
Illustration 198
(1) Bolts
(2) Cover

9. Install console cover (2) and bolts (1).

i01829953

Radiator Core - Clean

SMCS Code: 1353-070-KO

Open the engine compartment. The radiator core is

located at the rear of the machine.
g01265709
Illustration 200

Inspect the rollover protective structure (ROPS) for

cracks. Inspect the ROPS for any loose bolts or
damaged bolts. Replace the damaged bolts with
original equipment parts only.
128 KEBU7543-08
Maintenance Section
Seat Belt - Inspect

Note: Apply oil to all ROPS bolt threads before you Note: The seat belt should be replaced within 3 years
install the bolts. Failure to apply the oil to the threads of the date of installation. A date of installation label
can result in an improper bolt torque. is attached to the seat belt retractor and buckle. If the
date of installation label is missing, replace belt within
Replace the ROPS mounting support if the ROPS 3 years from the year of manufacture as indicated
rattles. on belt webbing label, buckle housing, or installation
tags (non-retractable belts).
Do not straighten the ROPS or repair the ROPS by
welding reinforcement plates to the ROPS.
i04421974

Consult your Caterpillar dealer for the repair of the

ROPS.
Seat Belt - Replace
SMCS Code: 7327-510
i04423622
The seat belt should be replaced within 3 years of
Seat Belt - Inspect the date of installation. A date of installation label is
attached to the seat belt retractor and buckle. If the
SMCS Code: 7327-040 date of installation label is missing, replace belt within
3 years from the year of manufacture as indicated
Always inspect the condition of the seat belt and the on belt webbing label, buckle housing, or installation
condition of the seat belt mounting hardware before tags (non-retractable belts).
you operate the machine. Replace any parts that are
damaged or worn before you operate the machine.

g01152685
Illustration 202
Typical Example
(1) Date of installation (retractor)
g02620101 (2) Date of installation (buckle)
Illustration 201
(3) Year of manufacture (tag) (fully extended Web)
Typical example (4) Year of manufacture (underside) (buckle)

Inspect buckle (1) for wear or for damage. If the Consult your Cat dealer for the replacement of the
buckle is worn or damaged, replace the seat belt. seat belt and the mounting hardware.

Inspect seat belt (2) for webbing that is worn or Determine age of new seat belt before installing on
frayed. Replace the seat belt if the webbing is worn seat. A manufacture label is on belt webbing and
or frayed. imprinted on belt buckle. Do not exceed install by
date on label.
Inspect all seat belt mounting hardware for wear or
for damage. Replace any mounting hardware that Complete seat belt system should be installed with
is worn or damaged. Make sure that the mounting new mounting hardware.
bolts are tight.
Date of installation labels should be marked and
If your machine is equipped with a seat belt affixed to the seat belt retractor and buckle.
extension, also perform this inspection procedure for
the seat belt extension. Note: Date of installation labels should be
permanently marked by punch (retractable belt) or
Contact your Cat dealer for the replacement of the stamp (non-retractable belt).
seat belt and the mounting hardware.
KEBU7543-08 129
Maintenance Section
Shell Kit Bolt Torque - Check

If your machine is equipped with a seat belt The metering pump is located under the front of the
extension, also perform this replacement procedure operator station.
for the seat belt extension.

i04286150
Crushing Hazard. Connect the steering frame lock
Shell Kit Bolt Torque - Check between front and rear frames before servicing the
(If Equipped) machine in the articulation area. Disconnect the
steering frame lock and secure it in the stored po-
SMCS Code: 6605-535-PA sition before resuming operation. Failure to do so
could result in serious injury or death.

Refer to Operation and Maintenance Manual,

“Steering Frame Lock” before entering the articulation
joint.

Note: Do not disconnect any hydraulic lines from the

metering pump.

Use the following steps to lubricate the splines on

the steering column:

g02453319
Illustration 203

There are eight bolts (1) that hold the two shell halves
together. Tighten the bolts in a sequential pattern in
order to maintain a uniform gap between the two
shell halves. Tighten the bolts to a torque of 460 N·m
(340 lb ft).

Refer to Special Instruction, REHS0712, “Shell Kit

Installation and Removal Procedure” for information
on the installation and removal of the shell kit.
g01554656
Illustration 205
i03063102 (1) Metering Pump
(2) Bolts
Steering Column Spline (HMU
1. Support the metering pump (1). Loosen the four
Steering) - Lubricate bolts (2) that hold the pump. Do not loosen the
hose couplings.
SMCS Code: 4310-086-SN; 4310-086-JF;
4338-086-SN; 4343-086-SN; 4343-086-JF

g01554657
Illustration 206
g01554654 (3) Splines
Illustration 204
130 KEBU7543-08
Maintenance Section
Steering Cylinder Ends - Lubricate

2. Lower the pump in order to expose the splines (3). Lower the steering frame lock pin into the locked
position.

Note: Wipe all of the fittings before you lubricate the

fittings.

g01560274
Illustration 207
(4) Rubber Boot

3. Inspect the rubber boot (4) that is located on the g01273078

steering column for wear. If necessary, replace Illustration 209
the boot.
1. There are two steering cylinders. One steering
4. Clean the male splines on the steering column. cylinder is on the right side of the machine and
Clean the female splines in the pump. one steering cylinder is on the left side of the
machine. Lubricate the front lube fitting (1) on
5. Apply a small amount of 186-1531 Molykote to each side of the machine.
the male splines and to the female splines.

6. Apply a small amount of 186-1531 Molykote

between the bottom of boot (4) and the seal for
the pump.

7. Push the pump into position.

8. Tighten the four bolts that hold the pump.

9. Test the steering system.

i02539507

Steering Cylinder Ends - Illustration 210

g01273080

Lubricate 2. Both the lubrication fittings for the rear end of the
SMCS Code: 4303-086-BD steering cylinders are located on the left side of
the machine. Lubricate the fittings (2) for the rear
end of the steering cylinders.

3. Raise the steering frame lock pin into the unlocked

position.

g01265444
Illustration 208
KEBU7543-08 131
Maintenance Section
Tire Inflation - Check

i02977178 High Pressure Limit – Adjust the tire pressure to

the high pressure limit in order to improve stability.
Tire Inflation - Check Raising the tire pressure will also reduce the flex in
the sidewall.
SMCS Code: 4203-535-PX
Maximum Shipping Pressure – Adjust the tire
The tire pressure in a warm shop area (18° to 21°C pressure to the maximum shipping pressure when
(65° to 70°F) average temperature) will significantly you ship the machine.
change when you move the machine into freezing
temperatures. If you inflate the tire to the correct Note: After shipping the machine, return the tire
pressure in a warm shop, the tire will be underinflated pressure to the correct operating pressure before
in freezing temperatures. Low pressure shortens the operating the machine.
life of a tire.
Table 19
When you operate the machine in freezing
Low Normal High Maximum
temperatures, see Operation and Maintenance Ply
Pressure Operating Pressure Shipping
Manual, SEBU5898, “Cold Weather Rating
Limit Pressure Limit Pressure
Recommendations”.
80 kPa 110 kPa 110 kPa 200 kPa
8
(12 psi) (16 psi) (16 psi) (30 psi)
Tire Inflation Pressure
80 kPa 110 kPa 140 kPa 200 kPa
10
(12 psi) (16 psi) (20 psi) (30 psi)
80 kPa 110 kPa 165 kPa 200 kPa
12
The liquid ballast in tires is an irritant. Protect the (12 psi) (16 psi) (24 psi) (30 psi)
eyes and face from the spray that comes out of 80 kPa 110 kPa 195 kPa 200 kPa
the valve stem when checking the ballast level in 14
(12 psi) (16 psi) (28 psi) (30 psi)
the tires or when checking the tires air pressure.
Failure to protect the eyes and face could result in
personal injury. Tire Ballast
The liquid ballast for tires is a solution of water and
The tires are filled with liquid ballast from the factory. calcium chloride powder CaCl. Calcium chloride
When you check the tire pressure, move the machine powder CaCl is an additive which will provide an
so that the valve stem for the tire is in the twelve antifreeze protection and additional weight. If a tire is
o'clock position in order to prevent the liquid ballast repaired or replaced, the tire must be filled with the
from spraying out of the valve stem. Use 1P-0545 correct amount of liquid ballast before the machine
Pressure Gauge for tires that are equipped with a returns to operation. The correct mixture for the liquid
liquid ballast. ballast is 300 grams (0.66 lb) of calcium chloride
powder CaCl2 per 1 L (0.26 US gal) of water. Fill each
Note: There will be a slight amount of liquid ballast tire with 430 L (114 US gal) of thirty percent calcium
in the valve stem after moving the machine into chloride and seventy percent water. The level of the
position. Depress the valve stem in order to allow the liquid ballast can be checked by using the following
liquid ballast to be blown out of the valve stem before procedure:
attaching the pressure gauge. Only use a pressure
gauge that is capable of handling liquid. 1. Move the machine to a flat surface and park the
machine with the valve stem in the 9 o'clock
Tire Operating Pressures position.

Since operating conditions can vary, inflate the tires 2. Remove the cap for the valve stem.
to the following pressures:
3. Check for fluid by depressing the stem in the valve
Low Pressure Limit – Adjust the tire pressure to stem. The liquid ballast should spray from the
the low pressure limit in order to improve traction. stem.
Lowering the tire pressure will also provide a
smoother ride. 4. Move the machine so that the valve stem is in the
12 o'clock position.
Normal Operating Pressure – Adjust the tire
pressure to the normal operating pressure when 5. Depress the stem in the valve stem. A light mist
special conditions do not exist. should spray from the valve stem.
132 KEBU7543-08
Maintenance Section
Tire Spacing - Change

i03162920

Tire Spacing - Change

SMCS Code: 4200-018; 4202-018; 4203-018

When the wheels are installed in the standard

configuration mud may accumulate between the
frame and tires. The wheels may be interchanged in
order to prevent the accumulation of mud.

Perform the following steps in order to interchange

the tires:

1. Engage the parking brake.

2. Block the drum.

3. Jack up the rear of the machine until the tires

are off the ground. Refer to Operation and
Maintenance Manual, “Additional Messages” for
the jacking up locations. g01622115
Illustration 212

5. Move wheel (1) from the left side of the machine

to the right side of the machine. Install wheel (1)
so that the inside of the wheel is now the outside.
Install the wheel nuts, refer to Operation and
Maintenance Manual, “Wheel Nuts - Tighten” for
the correct torque.

6. Move wheel (2) from the right side of the machine

to the left side of the machine. Install wheel (2)
so that the inside of the wheel is now the outside.
Install the wheel nuts, refer to Operation and
Maintenance Manual, “Wheel Nuts - Tighten” for
the correct torque.

Note: When the wheels are installed in the alternate

configuration the valve stem will be facing toward the
machine.

Note: When the wheels are installed in the alternate

configuration the width of the machine at the wheels
g01622099 becomes greater than the width at the drum. Consult
Illustration 211
with local regulations in order to address any
4. Remove the wheel nuts that hold wheel (1) and problems with operation or transportation.
the wheel nuts that hold wheel (2) and remove
the wheels.
KEBU7543-08 133
Maintenance Section
Vibratory Support Oil - Change

i02529445

Vibratory Support Oil - Change

SMCS Code: 5656-044-OC

g01265676
Illustration 215

4. Filler plug (1) is located at the top of the support.

g01265580
Note: When a machine is equipped with a sensor
Illustration 213 for the VPM gauge, there is a guard over the fill port
hole. The level check plug can be used as a filler
The vibratory support is located on the right side of plug in this case.
the drum.
5. Remove filler plug(1) and the level check plug (2).

6. Refer to the Operation and Maintenance Manual,

“Lubricant Viscosities and Capacities (Refill)”.

7. Fill the support until the oil is at the bottom of the

level check plug opening (2).

8. Clean plugs (1) and (2). Install plugs (1) and (2).

i02529429

Vibratory Support Oil Level -

Illustration 214
g01265692 Check
SMCS Code: 5656-535-FLV
1. Drain plug (3) is located at the bottom.

2. Remove drain plug (3). Drain the oil into a suitable

container. Dispose of the oil in an acceptable
manner.

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information that
pertains to containing fluid spillage.

3. After the oil is drained, clean the drain plug. Install

drain plug (3).

g01265580
Illustration 216

The vibratory support is located on the right side of

the drum.
134 KEBU7543-08
Maintenance Section
Vibratory Support Oil Sample - Obtain

Refer to the Special Publication, SEBU6250,

“Caterpillar Machine Fluids Recommendations” for
information on obtaining the oil sample.

Note: After you obtain an oil sample, add oil in order

to maintain the proper level.

i02797954

Wheel Nuts - Tighten

SMCS Code: 4201-527-NT; 4210-527
S/N: C7F1-Up
g01265676
Illustration 217 S/N: C8F1-Up

1. The level check plug (2) is located at the three S/N: P7F1-Up
o'clock position.
S/N: P8F1-Up
2. Remove level check plug (2). Check the level of S/N: C5P1-Up
the oil. Maintain the level of the oil at the bottom
of the level check plug opening. S/N: C6P1-Up

Note: When a machine is equipped with a sensor S/N: C8P1-Up

for the VPM gauge, there is a guard over the fill port
S/N: FCP1-Up
hole. The level check plug can be used as a filler
plug in this case. S/N: C5S1-Up
3. If the oil level is low, remove filler plug (1). S/N: C6S1-Up

4. In order to maintain the proper oil level, add oil. S/N: C8S1-Up
S/N: FCS1-Up
5. Refer to the Operation and Maintenance Manual,
“Lubricant Viscosities and Capacities (Refill)”.

6. Clean the plugs and install the plugs.

i02529353

Vibratory Support Oil Sample

- Obtain
SMCS Code: 5656-008

g01398024
Illustration 219

Tighten the wheel nuts to a torque of 460 ± 60 N·m

(340 ± 45 lb ft).

g01265580
Illustration 218
KEBU7543-08 135
Maintenance Section
Wheel Nuts - Tighten

i02797959 i01768519

Wheel Nuts - Tighten Window Wiper -

SMCS Code: 4201-527-NT; 4210-527 Inspect/Replace
S/N: C7L1-Up SMCS Code: 7305-040; 7305-510

S/N: JCP1-Up
S/N: JCS1-Up
S/N: CYX1-Up

g00904438
Illustration 222

Inspect the front windshield wiper blade and the rear

windshield wiper blade. If necessary, replace the
windshield wiper blades.
g01398024
Illustration 220
i00851568
Tighten the wheel nuts to a torque of 630 ± 80 N·m
(465 ± 60 lb ft). Windows - Clean
SMCS Code: 7310-070; 7340-070
i01738094

Window Washer Reservoir - Use commercially available window cleaning

solutions in order to clean the windows. Clean the
Fill outside of the cab windows from the ground unless
handholds are available.
SMCS Code: 7306-544; 7306-544-KE; 7306

g00890165
Illustration 221

The window washer reservoir is located on the right

side of the cab.

If the level of the cleaning solution is low, refill the

reservoir.