MAINTENANCE INTERVALS

Operation and Maintenance

Manual Excerpt

® ®
© 2010 Caterpillar
All Rights Reserved
 SEBU7469-03
February 2007

Operation and
Maintenance
Manual
12H Motor Grader
1251-Up (Machine)
CBK1-Up (Machine)
AMZ1-Up (Machine)
SEBU7469-03 77
Maintenance Section
Maintenance Interval Schedule

i02704892 Every 100 Service Hours or 2 Weeks

Maintenance Interval Schedule Articulation Bearings - Lubricate ........................... 80
Axle Oscillation Bearings - Lubricate .................... 80
SMCS Code: 1000; 7000 Belt - Inspect ......................................................... 81
Blade Lift Cylinder Socket - Lubricate ................... 83
When Required Cab Air Filter - Clean/Replace .............................. 85
Centershift Cylinder Socket - Lubricate ................ 86
Battery - Recycle .................................................. 81 Centershift Lock Bar - Clean/Lubricate ................. 86
Belt - Replace ....................................................... 82 Drawbar Ball and Socket - Lubricate .................... 99
Blade Lift Cylinder Socket - Check/Adjust/ Fuel Tank Water and Sediment - Drain ................ 115
Replace ............................................................... 83 Hydraulic System Oil Level - Check ................... 120
Centershift Cylinder Socket - Check/Adjust/ Kingpin Bearings - Lubricate ............................... 121
Replace ............................................................... 85 Ripper Cylinder Bearings - Lubricate .................. 124
Circle Clearances - Check/Adjust ......................... 86 Scarifier Lift Link Socket - Lubricate ................... 126
Circle Drive Oil Level - Check ............................... 90 Tandem Drive Oil Level - Check ......................... 128
Circuit Breakers - Reset ........................................ 91 Tire Inflation - Check ........................................... 129
Cutting Edges and End Bits - Inspect/Replace ..... 98 Wheel Bearing Oil Level (Front) - Check ............ 134
Drawbar Ball and Socket End Play - Wheel Lean Bar Bearings - Lubricate ................. 134
Check/Adjust ....................................................... 99 Wheel Lean Bearings - Lubricate ....................... 134
Engine Air Filter Primary Element - Clean/ Wheel Lean Cylinder Bearings - Lubricate ......... 135
Replace ............................................................. 100
Engine Air Filter Secondary Element - Replace .. 102 Initial 500 Service Hours (or at first oil
Engine Air Filter Service Indicator Screen - change)
Check/Replace .................................................. 104
Engine Crankcase Breather - Replace ............... 105 Battery or Battery Cable - Inspect/Replace .......... 81
Engine Overheating ............................................ 108 Engine Valve Lash - Check ................................. 109
Engine Power Loss ............................................. 109
Evaporator Coil and Heater Coil - Clean ............. 110 Initial 500 Hours (for New Systems, Refilled
Fuel System - Fill ................................................. 111 Systems, and Converted Systems)
Fuel System - Prime ............................................ 112
Fuses - Replace ................................................... 115 Cooling System Coolant Sample (Level 2) -
Moldboard Wear Strip - Inspect/Adjust/Replace .. 121 Obtain ................................................................. 93
Oil Filter - Inspect ................................................ 122
Radiator - Clean .................................................. 123 Every 500 Service Hours or 3 Months
Radiator Core - Clean ......................................... 123
Ripper Tip - Inspect/Replace .............................. 124 Air Dryer - Check .................................................. 79
Scarifier Teeth - Inspect/Replace ........................ 126 Braking System - Test ........................................... 84
Steering Accumulator - Check ............................ 127 Cooling System Coolant Sample (Level 1) -
Window Washer Reservoir - Fill .......................... 135 Obtain ................................................................. 92
Window Wiper - Inspect/Replace ........................ 135 Engine Air Filter Service Indicator -
Windows - Clean ................................................. 136 Inspect/Replace ................................................ 103
Engine Oil Sample - Obtain ................................ 105
Every 10 Service Hours or Daily Engine Oil and Filter - Change ........................... 106
Fuel System Secondary Filter - Replace ............. 113
Air Tank Moisture and Sediment - Drain ............... 80 Fuel System Water Separator Element -
Backup Alarm - Test .............................................. 81 Replace .............................................................. 114
Brakes, Indicators and Gauges - Test ................... 83 Fuel Tank Cap and Strainer - Clean .................... 115
Circle Drive Pinion Teeth - Lubricate .................... 90 Hydraulic System Oil Filter - Replace .................. 119
Circle Top - Lubricate ............................................ 91 Hydraulic System Oil Sample - Obtain ............... 121
Cooling System Coolant Level - Check ................ 96 Parking Brake - Drain ......................................... 122
Engine Air Filter Service Indicator - Inspect ........ 102 Tandem Breather - Clean/Replace ..................... 128
Engine Air Precleaner - Clean ............................ 104 Tandem Drive Oil Sample - Obtain ..................... 129
Engine Oil Level - Check .................................... 105 Transmission and Differential Oil Filter and Screens -
Fuel System Water Separator - Drain .................. 113 Replace/Clean .................................................. 131
Seat Belt - Inspect .............................................. 126 Transmission and Differential Oil Sample -
Transmission and Differential Oil Level - Check .. 132 Obtain ............................................................... 133

Initial 100 Service Hours Every 1000 Service Hours or 6 Months

Transmission and Differential Oil Filter and Screens - Blade Cushion Accumulator - Check .................... 82
Replace/Clean .................................................. 131 Rollover Protective Structure (ROPS) - Inspect .. 125
78 SEBU7469-03
Maintenance Section
Maintenance Interval Schedule

Transmission and Differential Oil - Change ........ 129

Every 2000 Service Hours or 2 Years

Air Dryer Desiccant - Replace .............................. 79
Battery or Battery Cable - Inspect/Replace .......... 81
Circle Drive Oil - Change ...................................... 89
Condenser (Refrigerant) - Clean .......................... 91
Cooling System Pressure Cap - Clean/Replace ... 96
Crankshaft Vibration Damper - Inspect ................. 98
Engine Valve Lash - Check ................................. 109
Engine Valve Rotators - Inspect ......................... 109
Evaporator Coil and Heater Coil - Clean ............. 110
Final Drive Preload - Check ................................. 110
Refrigerant Dryer - Replace ................................ 124
Tandem Drive Oil - Change ................................ 128
Wheel Bearing Oil (Front) - Change ................... 133

Every Year
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 93

Every 3 Years After Date of Installation or

Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 127

Every 3000 Service Hours or 3 Years

Cooling System Water Temperature Regulator -
Replace ............................................................... 97

Every 4000 Service Hours

Hydraulic System Oil - Change ............................ 118

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 ............. 93
SEBU7469-03 79
Maintenance Section
Air Dryer - Check

i01862160 5. Close the access door.

Air Dryer - Check Note: Small amounts of moisture may be in the
system due to condensation in the system. Moisture
SMCS Code: 4285-535 may also be in the system if an air dryer is installed
on a machine that has been operating without an air
dryer. Several weeks may be required in order to
completely dry the system.
The air lines to and from the air dryer must be at
atmospheric pressure. If the air lines are not at at-
i01862178
mospheric pressure, personal injury could result.
Release the air pressure from the air system com- Air Dryer Desiccant - Replace
pletely before performing maintenance.
SMCS Code: 4285-510
Refer to the Operation and Maintenance Manual,
“Access Doors and Covers” for the location of the
service points.
The air lines to and from the air dryer must be at
The air dryer is positioned on the left side at the rear atmospheric pressure. If the air lines are not at at-
of the machine. mospheric pressure, personal injury could result.
Release the air pressure from the air system com-
1. Open the access door in order to service the air pletely before performing maintenance.
dryer.
Refer to the Operation and Maintenance Manual,
“Access Doors and Covers” for the location of the
service points.

g00949269
Illustration 77

2. Turn drain valve (1) to the 3:00 position in order

to drain one air tank. Turn drain valve (1) to the g00949272
Illustration 78
9:00 position in order to drain the other air tank.
The air tanks are positioned in the service center
at the rear of the machine. Air dryer (1) is positioned on the left side at the rear
of the machine.
3. Check for moisture in the air tanks. Close the drain
valve for the air tanks. 1. Open the access door in order to service the air
dryer.
4. If moisture is present in the air tanks, replace the
desiccant cartridge for air dryer (2). Consult your 2. Replace the air dryer desiccant cartridge when
Caterpillar dealer for information about replacing the water can not be absorbed. Consult your
the desiccant cartridge. Caterpillar dealer for service or for replacement
parts.
80 SEBU7469-03
Maintenance Section
Air Tank Moisture and Sediment - Drain

3. Close the access door.

i01862632

Air Tank Moisture and

Sediment - Drain
SMCS Code: 4272-543-M&S; 5505-543

Refer to the Operation and Maintenance Manual,

“Access Doors and Covers” for the location of the
access doors.

1. Open the access door in order to service the drain g00811301

valve for moisture and sediment. Illustration 80

The upper articulation bearing has one fitting (1).

In order to lubricate the upper articulation bearing,
use 183-3424 Grease Cartridge to apply lubricant
through fitting (1).

The lower articulation bearing has one fitting (2).

In order to lubricate the lower articulation bearing,
use 183-3424 Grease Cartridge to apply lubricant
through fitting (2).

i01671028

Axle Oscillation Bearings -

Lubricate
SMCS Code: 3268; 4313

The lubrication fitting is located in the middle of the

front axle. Wipe the fitting before you apply lubricant
g00949522 to the fitting.
Illustration 79

2. The air tanks are located in the rear compartment

of the machine behind the left side of the engine.
Turn drain valve (1) to the 3:00 position in order
to drain one air tank. Turn drain valve (1) to the
9:00 position in order to drain the other air tank.
Close the drain valve.

3. Close the access door.

i01671010

Articulation Bearings -
Lubricate Illustration 81
g00811688

SMCS Code: 7057-086-BD In order to lubricate the axle oscillation bearings, use
183-3424 Grease Cartridge to apply lubricant to the
Wipe all the fittings before you apply lubricant through one fitting.
the fittings. The fittings for the articulation bearings
are located under the cab on the left side of the
machine.
SEBU7469-03 81
Maintenance Section
Backup Alarm - Test

i02307698 5. Disconnect the positive battery cable from the

battery.
Backup Alarm - Test
6. Inspect the battery terminals for corrosion. Inspect
SMCS Code: 7406-081 the battery cables for wear or damage.
Turn the engine start switch to the ON position in 7. If necessary, make repairs. If necessary, replace
order to perform the test. the battery cable or the battery.
Apply the service brake. Move the transmission 8. Connect the positive battery cable at the battery.
control (lever) to the REVERSE position.
9. Connect the negative battery cable at the battery.
The backup alarm should sound immediately.
The backup alarm should continue to sound until 10. Connect the battery cable at the battery
the transmission control (lever) is moved to the disconnect switch.
NEUTRAL position or to any FORWARD position.
11. Install the key for the battery disconnect switch.
The backup alarm is located at the rear of the Turn the battery disconnect switch to the ON
machine. position.

i00993589 i01547509

Battery - Recycle Belt - Inspect

SMCS Code: 1401-561 SMCS Code: 1357-040; 1397-040
Always recycle a battery. Never discard a battery. Refer to the Operation and Maintenance Manual,
“Access Doors and Covers” for the location of the
Always return used batteries to one of the following service points.
locations:
Note: If a new belt is installed, check the film on belt
• A battery supplier tightener (2) after 30 minutes of operation. A belt is
considered to be used after 30 minutes of operation.
• An authorized battery collection facility
1. Stop the engine in order to inspect the belt.
• Recycling facility
2. Open the access door in order to service the belt.
i01770781

Battery or Battery Cable -

Inspect/Replace
SMCS Code: 1401-510; 1402-510

1. Turn the engine start switch key to the OFF

position. Turn all the switches to the OFF position.

2. Turn the key for the battery disconnect switch to

the OFF position. Remove the key.

3. Disconnect the negative battery cable at the

battery disconnect switch. The battery disconnect
switch is connected to the machine frame.

Note: Do not allow the disconnected battery cable to

contact the battery disconnect switch or the machine.

4. Disconnect the negative battery cable from the

battery.
82 SEBU7469-03
Maintenance Section
Belt - Replace

g00804338 g00804338
Illustration 82 Illustration 83

3. Inspect the condition of belt (1). 1. Release the tension on belt (1). Insert a 12.7 mm
(0.50 inch) ratchet into the square hole in belt
4. Make sure that the free arm stop on the arm of the tightener (2) and pry the belt tightener in a
belt tightener is aligned with the heavy black line clockwise direction.
on the decal that is on belt tightener (2). If the free
arm stop is in the red area, replace the belt. 2. Remove the belt.

3. Install the new belt around the pulleys. This is

i01547516
shown in Illustration 83.
Belt - Replace
i01564804
SMCS Code: 1357-510; 1397-510
Blade Cushion Accumulator -
Refer to the Operation and Maintenance Manual,
“Access Doors and Covers” for the location of the
Check
service points.
SMCS Code: 5077-535-BG

Consult your Caterpillar dealer for the following

information:

• The correct checking procedure

• The correct filling procedures
SEBU7469-03 83
Maintenance Section
Blade Lift Cylinder Socket - Check/Adjust/Replace

• The recommended pressure i01862405

Blade Lift Cylinder Socket -

i01862399
Lubricate
Blade Lift Cylinder Socket -
SMCS Code: 5102-086; 5103-086
Check/Adjust/Replace
Wipe all the fittings before you apply lubricant to the
SMCS Code: 5102-025; 5102-510; 5102-535; fittings.
5103-025; 5103-510; 5103-535

1. Rotate the blade. Position the blade at an angle

of 90 degrees to the frame. Lower the blade to
the ground.

2. Operate the blade lift cylinders. Observe the

socket. If the socket moves without blade
movement, adjustment is necessary.

g00949369
Illustration 85

There are two blade lift cylinders (1).

Each blade lift cylinder socket has one fitting (2).

In order to lubricate the blade lift cylinder sockets,
use 183-3424 Grease Cartridge to apply lubricant
to each fitting.
g00949365
Illustration 84
i01828321
3. Remove two bolts (2) from each cap (1). Remove
the cap (1). Brakes, Indicators and Gauges
4. Remove one shim from either side of the inserts in
- Test
order to reduce clearance. SMCS Code: 4251-081; 4267-081; 4269-081;
7000-081; 7450-081; 7490-081
Note: If you need to remove two shims, then remove
one shim from each side of the inserts.

5. Install the cap. Install the bolts and tighten the

bolts.

6. Check the socket for movement. If you observe

movement in the socket, repeat Step 3 through
Step 5.

Note: If no shims remain, install new inserts. Install

two shims on each side of the inserts. Add additional
shims, as needed.

g00932610
Illustration 86

Look for broken lenses on the gauges, broken

indicator lights or broken switches, etc.
84 SEBU7469-03
Maintenance Section
Braking System - Test

Start the engine. Run the engine until the gauges Use the following test in order to determine whether
have stabilized. the service brake is functional. This test is not
intended to measure the maximum holding ability of
Look for inoperative gauges. the service brake.

Turn on all of the machine lights. Check for proper 1. Start the engine. Raise the blade slightly. Depress
operation. the transmission modulator control. Apply the
service brake control.
Sound the horn.
2. Move the transmission control (lever) to FIFTH
Move the machine forward and test the service SPEED FORWARD. Increase the engine speed
brakes. If the service brakes do not function properly, to high idle.
see Operation and Maintenance Manual, “Braking
System - Test” in the Maintenance Interval Schedule 3. Gradually release the transmission modulator
of this manual. control. The machine should not move. The
engine should stall.
Stop the engine.
4. Reduce the engine speed to low idle. Engage
Make any needed repairs before you operate the the parking brake control. Lower the blade to the
machine. ground. Stop the engine.

Note: The friction material for the brake may require

i01998856
replacement. The new friction material for the brake
Braking System - Test may require burnishing for maximum performance.
For the procedure to burnish the new friction material
SMCS Code: 3077-081; 4011-081; 4250-081; for the brake, consult your Caterpillar dealer.
4251-081; 4267-081
Parking Brake Holding Ability Test
Service Brake Holding Ability Test

Personal injury can result if the machine moves

Personal injury can result if the machine moves while testing.
while testing.
It the machine begins to move during test, reduce
If the machine begins to move during test, reduce the engine speed immediately and engage the ser-
the engine speed immediately and engage the vice brake control.
parking brake.
NOTICE
NOTICE If the machine moved while testing the parking brake,
If the machine begins to move, reduce the engine consult your Caterpillar dealer.
speed immediately and engage the parking brake.
Have the dealer inspect and, if necessary repair the
parking brake before returning the machine to opera-
NOTICE tion.
If the machine moved while testing the service brake
consult your Caterpillar dealer. Be sure that the area around the machine is clear of
personnel and clear of obstacles.
Have the dealer inspect and, if necessary, repair the
service brakes before returning the machine to oper- Test the parking brake on a hard dry surface.
ation.
Fasten the seat belt before you test the parking
Make sure that the area around the machine is clear brake.
of personnel and clear of obstacles.
Use the following test to determine whether the
Test the service brake on a dry level surface. parking brake is functional. This test is not intended
to measure the maximum holding ability of the
Fasten your seat belt before you test the brakes. parking brake.
SEBU7469-03 85
Maintenance Section
Cab Air Filter - Clean/Replace

1. Position the machine on a slope of 20 percent. 3. Rinse the filter elements in clean water.
Thoroughly air dry the filter elements.
2. Engage the parking brake control. Release the
service brake control. The wheels should not 4. Install the filter elements. Install the filter cover.
rotate. If the wheels rotate, engage the service
brake control.
Replace the Filters
i01829689 Note: Replace the cab air filters, as required.

Cab Air Filter - Clean/Replace 1. Remove the filter covers.

SMCS Code: 7311-070-FI; 7311-510-FI; 7342-070; 2. Remove the filter elements. Discard the filter
7342-510 elements.

Note: The cab air filters are an optional attachment 3. Install the new filter elements.
on this machine.
4. Install the filter covers.

i01828752

Centershift Cylinder Socket -

Check/Adjust/Replace
SMCS Code: 5223-023; 5223-025; 5223-535

1. Rotate the blade. Place the blade at an angle of

90 degrees to the frame. Lower the blade to the
ground.

2. Operate the centershift cylinder. Observe the

socket. If the socket moves without movement of
the drawbar, adjustment is necessary.

g00933775
Illustration 87
(1) Outside filter
(2) Inside filter

Clean the Filters

Note: Clean the cab air filters more often in dusty
conditions.

The cab air system has two outside filters. There is

one outside filter above each cab door. Illustration 88
g00932998

The filter for the inside cab air system is positioned 3. Remove bolts (1) from cap (2). Remove cap (2).
behind the operator’s seat.
4. Remove one shim from either side of the inserts in
1. Remove the filter cover. order to reduce clearance.

2. Remove the filter elements. Clean the filter Note: If you need to remove two shims, then remove
elements with pressure air or wash the filter one shim from each side of the inserts.
elements in warm water and in a nonsudsing
household detergent. 5. Install the cap and bolts and tighten the bolts.
86 SEBU7469-03
Maintenance Section
Centershift Cylinder Socket - Lubricate

6. Check the socket for movement. If you observe

movement in the socket, repeat Step 3 through
Step 5.

Note: If no shims remain, install new inserts. Install

two shims on each side of the socket. Add additional
shims, as needed.

i01862638

Centershift Cylinder Socket -

Lubricate
SMCS Code: 5223-086 g00811486
Illustration 90
Wipe all the fittings before you apply lubricant to the
fittings. Centershift lock bar (1) is located under the front
frame and above the circle.

Clean the dirt, the lubricant and the rust from the
holes in the centershift lock bar.

Apply the appropriate lubricant to the holes in the

centershift lock bar.

i01865351

Circle Clearances -
Check/Adjust
SMCS Code: 6152-025; 6152-535; 6153-025;
Illustration 89
g00949526 6153-535; 6154-025; 6154-535; 6155-025;
6155-535
The centershift cylinder has one fitting on each end.
In order to lubricate the centershift cylinder sockets, Blade Circle and Drawbar
use 183-3424 Grease Cartridge (5% Molybdenum
Disulfide) to apply lubricant to the fittings. 1. Rotate the blade. Place the blade at an angle of
90 degrees to the frame.
i02327869
Note: Install the C-clamps before you lower the blade
Centershift Lock Bar - to the ground.
Clean/Lubricate
SMCS Code: 5221-070; 5221-086

Note: Caterpillar recommends the use of 5%

molybdenum grease for lubricating the centershift
lock bar. Refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for
more information on molybdenum grease.
SEBU7469-03 87
Maintenance Section
Circle Clearances - Check/Adjust

Blade Circle to Shoe Clearance

1. Rotate the blade. Place the blade at an angle of
90 degrees to the frame.

Note: Install the C-clamps before you lower the blade

to the ground.

g00950750
Illustration 91

g00950750
Illustration 93

g00774795
Illustration 92

2. Clamp two C-clamps onto the front of the blade

circle (1) and the drawbar (2). This will fasten the
blade circle and the drawbar together. Tighten
the two C-clamps until the wear strips (3) are in
contact with the top of the blade circle and the
wear strips (3) are in contact with the bottom of Illustration 94
g00774796
the drawbar.
2. Clamp two C-clamps onto the front of the blade
3. Lower the blade to the ground. Stop the engine. circle (1) and the drawbar (2). Tighten both
C-clamps until the wear strips (3) contact the top
4. Measure the distance (A) that is between the top of the circle and the bottom of the drawbar.
surface of the blade circle and the bottom surface
of the drawbar. Replace the wear strip (3), if the 3. Lower the blade to the ground. Stop the engine.
distance between the top surface of the blade
circle and the bottom surface of the drawbar is Note: Check the wear strips (3) around the entire
less than 1.5 mm (0.06 inch). circumference of the blade circle. The wear strips (3)
should be in complete contact with the blade circle
5. Inspect the wear strip (3). Inspect the drawbar. and the drawbar.
The wear strip (3) should be in complete contact
at all points with the blade circle. If the wear strip
(3) is not in complete contact with the blade circle,
replace the wear strip (3).
88 SEBU7469-03
Maintenance Section
Circle Clearances - Check/Adjust

9. After all the circle shoes (9) have been adjusted,

check the circle shoes (9) for proper clearance.
If necessary, perform adjustments to the circle
shoes (9).

Note: After all the adjustments have been performed,

the blade circle (1) must rotate freely without binding .

Circle Pinion and Circle

Note: The engagement of the circle pinion and the
circle teeth is determined by the adjustment of the
circle shoes. Clean the circle and the pinion. Remove
any dirt and any abrasive material. This will reduce
Illustration 95
g00108090 wear to the circle pinion and to the circle teeth. Also,
this will improve the accuracy of the adjustment of
4. Shoe mounting fastener (4), shoe mounting the circle shoes. After the adjustment, apply clean
fastener (5) and shoe mounting fastener (6) must lubricant to the circle pinion and to the circle teeth.
be tight. Make sure that the shoe wear strips (3)
are completely seated in the circle shoes. 1. Rotate the blade. Place the blade at an angle
of 90 degrees to the frame. Lower the blade to
the ground. As you slowly inch the machine in a
forward direction, apply the service brake. This
will hold a light load between the wear strips for
the front circle shoes and the circle. Engage the
parking brake. Stop the engine.

g00774798
Illustration 96

5. Measure the clearance (B) between the bottom of

the circle (1) and the top of the shoe wear strip
(7). Maintain a maximum clearance of 0.5 mm
(0.02 inch). Maintain the proper clearance by g00775404
adding shims (8) or by removing shims (8). Illustration 97

Note: The proper clearance will permit the blade 2. Measure the clearance (X) that is between
circle to freely rotate for 360 degrees. the bottom flange of pinion (10) and the inner
machined surface of circle (1). If the clearance is
Adjust the circle shoes (9) one at a time. less than 49.5 to 52.5 mm (1.95 to 2.07 inch), then
adjust the clearance.
6. Loosen shoe mounting fastener (6). Remove shoe
mounting fastener (4) and remove shoe mounting
fastener (5).

7. Add shims or remove shims, as required.

8. Install shoe mounting fastener (4) and install shoe

mounting fastener (5). Tighten the shoe mounting
fasteners.
SEBU7469-03 89
Maintenance Section
Circle Drive Oil - Change

11. Tighten all shoe mounting fasteners (4), shoe

mounting fasteners (5) and all shoe mounting
fasteners (6) to a torque of 475 ± 60 N·m
(350 ± 44 lb ft).

12. Tighten all locknuts (11) to a torque of

200 ± 30 N·m (150 ± 22 lb ft).

i01862702

Circle Drive Oil - Change

SMCS Code: 5207-510-OC

g00774800 NOTICE
Illustration 98
Care must be taken to ensure that fluids are contained
3. Loosen shoe mounting fastener (4), shoe during performance of inspection, maintenance, test-
mounting fastener (5), shoe mounting fastener (6) ing, adjusting and repair of the product. Be prepared to
and locknuts (11) on the front circle shoes. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
4. Loosen the shoe mounting fasteners and the nent containing fluids.
locknuts for the rear circle shoes.
Refer to Special Publication, NENG2500, “Caterpillar
5. Loosen the shoe mounting fasteners and the Tools and Shop Products Guide” for tools and supplies
locknuts for the side circle shoes, if equipped. suitable to collect and contain fluids on Caterpillar
products.
6. Adjust the front circle shoes one at a time.
Turn the adjusting bolts (12) inward or turn the Dispose of all fluids according to local regulations and
adjusting bolts (12) outward in order to attain mandates.
49.5 to 52.5 mm (1.95 to 2.07 inch). Adjust the
other front circle shoe. Clean the area around the drain plug and clean the
area around the check/fill plug before you remove
Note: If the circle shoes are moved outward, it may the plugs.
be necessary to slowly inch the machine in a forward
direction in order to place a light load between the
wear strips for the front circle shoes and the circle.

Note: Adjust the front shoes so that the front circle

shoes have the same clearance measurement.

7. If you cannot attain the correct clearance

measurement due to worn front shoe wear strips
(7), replace the worn shoe wear strips (7). Then,
repeat Step 6.

8. Tighten the shoe mounting fasteners and locknuts

for the front circle shoes.

Note: The adjusting bolts must be tight against Illustration 99

g00108105
the circle shoes before you tighten the mounting Bottom view of the blade circle.
fasteners and the locknuts.

9. Set all of the circle shoes (front, side and rear)

to contact the circle. There will be no clearance
between the circle shoes and the circle.

10. When the pinion clearance is set and the front

circle shoes are in contact with the blade circle,
measure the distance (C) between each wear strip
(7) and the blade circle. The clearance should be
a maximum of 0.8 mm (0.03 inch).
90 SEBU7469-03
Maintenance Section
Circle Drive Oil Level - Check

g00949554 g00949563
Illustration 100 Illustration 101

1. Remove drain plug (1). Remove the check/fill plug 1. Remove check/fill plug (1).
(2). Allow the oil to drain into a suitable container.
2. Maintain the oil level to the bottom of the opening
2. Clean the drain plug and install the drain plug. for the check/fill plug.

3. Fill the circle drive housing with oil. See Operation 3. Install check/fill plug (1).
and Maintenance Manual, “Capacities (Refill)”.
i01674538
4. Clean the check/fill plug and install the check/fill
plug. Circle Drive Pinion Teeth -
5. Start the engine. Operate the machine for a few Lubricate
minutes. Check the circle drive housing for leaks.
SMCS Code: 5207-086-PI
6. Stop the engine. Remove the check/fill plug and
check the oil level. Maintain the oil level to the The circle drive pinion teeth are located under the
bottom of the filler opening. If necessary, add oil. circle drive housing.

7. Install the check/fill plug.

i01862720

Circle Drive Oil Level - Check

SMCS Code: 5207-535-OC

If a leak develops or you suspect a leak, check the

oil level.

Wipe the surfaces around the opening for the

check/fill plug before you check the oil and before
you add oil. g00774664
Illustration 102

The check/fill plug is located on top of the circle drive

1. Clean the dirt and the old lubricant from blade
housing at the front of the circle.
circle (1) and from circle drive pinion teeth (2).

2. Use 183-3424 Grease Cartridge (5%

Molybdenum Disulfide) in order to apply lubricant
to blade circle (1). Also use 183-3424 Grease
Cartridge (5% Molybdenum Disulfide) in order to
apply lubricant to circle drive pinion teeth (2).
SEBU7469-03 91
Maintenance Section
Circle Top - Lubricate

i01863885

Circle Top - Lubricate

SMCS Code: 6154-086-TP

1. Park the machine on a level surface and engage

the parking brake.

2. Stop the engine. Lower the blade and any

attachments to the ground.

g00933043
Illustration 104

The circuit breaker resets are located in the right rear

compartment of the machine.

Engine Circuit Breaker (1) – The circuit

breaker for the engine control is 15 amp.

Main Circuit Breaker (2) – The main

circuit breaker is 80 amp.

g00805334
Illustration 103

3. Apply a dry film lubricant to the 5 mm (0.2 inch) Alternator (3) – The circuit breaker for the
gap between the circle and the drawbar yoke. alternator is 80 amp.
Apply the dry film lubricant around the entire circle.
See Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations”, “Dry Film
Lubricant” for further information.

i01828809 i01863729

Circuit Breakers - Reset Condenser (Refrigerant) -

SMCS Code: 1417-529; 1420-529
Clean
SMCS Code: 1805-070
Refer to the Operation and Maintenance Manual,
“Access Doors and Covers” for the location of the
service points. NOTICE
If excessively dirty, clean condenser with a brush. To
Circuit Breaker Resets – Push the buttons inward prevent damage or bending of the fins, do not use a
in order to reset the circuit breakers. If the system is stiff brush.
working properly, the buttons will remain depressed.
If the buttons do not stay depressed, check the Repair the fins if found defective.
appropriate electrical circuit.
Refer to the Operation and Maintenance Manual,
“Access Doors and Covers” for the location of the
service points.
92 SEBU7469-03
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain

g00950115 g00809372
Illustration 105 Illustration 106

The refrigerant condenser (2) is located in front of the Refer to the Operation and Maintenance Manual,
radiator (1) at the rear of the machine. “Access Doors and Covers” for the location of the
service points.
1. Open the access door at the rear of the machine
on the left side of the machine. Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order
2. Inspect the condenser for debris. If necessary, to receive the full effect of S·O·S analysis, you
clean the condenser. must establish a consistent trend of data. In order
to establish a pertinent history of data, perform
3. Use clean water in order to wash off all dust and consistent samplings that are evenly spaced.
dirt from the condenser. Supplies for collecting samples can be obtained from
your Caterpillar dealer.
4. Close the access door.
Use the following guidelines for proper sampling of
the coolant:
i01889947

Cooling System Coolant • Complete the information on the label for the
sampling bottle before you begin to take the
Sample (Level 1) - Obtain samples.

SMCS Code: 1395-554 • Keep the unused sampling bottles stored in plastic
bags.
NOTICE
Always use a designated pump for oil sampling, and • Obtain coolant samples directly from the coolant
use a separate designated pump for coolant sampling. sample port. You should not obtain the samples
Using the same pump for both types of samples may from any other location.
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor- • Keep the lids on empty sampling bottles until you
rect interpretation that could lead to concerns by both are ready to collect the sample.
dealers and customers.
• Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid
Note: Level 1 results may indicate a need for contamination.
Level 2 Analysis.
• Never collect samples from expansion bottles.
• Never collect samples from the drain for a system.
Submit the sample for Level 1 analysis.

For additional information about coolant analysis, see

Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” or consult your Caterpillar
dealer.
SEBU7469-03 93
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain

i01892490 i01830361

Cooling System Coolant Cooling System Coolant (ELC)

Sample (Level 2) - Obtain - Change
SMCS Code: 1395-554 SMCS Code: 1350-044-NL; 1350-544-NL;
1395-044-NL
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 Personal injury can result from hot coolant, steam
contaminate the samples that are being drawn. This and alkali.
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both At operating temperature, engine coolant is hot
dealers and customers. and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly to

relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.

Do not attempt to tighten hose connections when

the coolant is hot, the hose can come off causing
burns.

Cooling System Coolant Additive contains alkali.

Avoid contact with skin and eyes.
g00809372
Illustration 107
NOTICE
Refer to the Operation and Maintenance Manual, Do not change the coolant until you read and under-
“Access Doors and Covers” for the location of the stand the material in the Cooling System Specifica-
service points. tions section.

Obtain the sample of the coolant as close as possible NOTICE

to the recommended sampling interval. Supplies Mixing Cat Extended Life Coolant (ELC) with other
for collecting samples can be obtained from your
products reduces the effectiveness of the coolant
Caterpillar dealer. and shortens coolant life. Use only Caterpillar prod-
ucts or commercial products that have passed the
Refer to Operation and Maintenance Manual,
Caterpillar EC-1 specifications for premixed or con-
“Cooling System Coolant Sample (Level 1) - Obtain” centrate coolants. Use only Cat Extender with Cat
for the guidelines for proper sampling of the coolant. ELC. Failure to follow these recommendations could
result in damage to the cooling systems components.
Submit the sample for Level 2 analysis.
If ELC cooling system contamination occurs, refer to
For additional information about coolant analysis, see
Operation and Maintenance, “Extended Life Coolant
Special Publication, SEBU6250, “Caterpillar Machine (ELC)” under the topic ELC Cooling System Contam-
Fluids Recommendations” or consult your Caterpillar ination.
dealer.
This machine was factory filled with Cat Extended Life
Coolant.
94 SEBU7469-03
Maintenance Section
Cooling System Coolant (ELC) - Change

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and g00934396

Illustration 108
mandates.
2. Open the cover. Slowly remove cooling system
If the coolant in the machine is changed to Extended pressure cap (1) in order to relieve pressure.
Life Coolant from another type of coolant, see Special
Publication, SEBU6250, “Extended Life Coolant
(ELC) Cooling System Maintenance”.

If the coolant is dirty or if you observe any foaming

in the cooling system, change the coolant before the
recommended interval.

It is important to replace the thermostat in order

to avoid any unexpected failure of the thermostat.
This is a good preventive maintenance practice that
reduces the chances of unscheduled downtime.
Failure to replace the thermostat on a regularly
scheduled basis could cause severe engine damage.
g00779160
Note: If you are only replacing the thermostat, drain Illustration 109
the coolant from the cooling system so that the level
of the coolant is below the thermostat housing. 3. Open drain valve (3). Drain valve (3) is located
on the water line at the lower right side of the
Always operate Caterpillar engines with a thermostat engine. Open drain valve (2). Drain valve (2) is
because these engines have a shunt design cooling located under the left side of the radiator. Allow
system. the coolant to drain into a suitable container.

Note: Thermostats can be reused if the thermostats 4. Flush the cooling system with clean water until the
meet certain test specifications. The tested draining water is transparent.
thermostats must not be damaged and the tested
thermostats must not have an excessive buildup of 5. Close the drain valves.
deposits.
6. Add the Extended Life Coolant. Refer to Operation
1. Stop the engine and allow the engine to cool. and Maintenance Manual, “Capacities (Refill)”.

Note: Make sure that cooling system pressure cap

(1) is removed for Steps 7 through 8.

7. Start the engine and run the engine until the

thermostat opens and the coolant level stabilizes.

8. Maintain the coolant level within 13 mm (.5 inch)

of the bottom of the filler tube.

9. Install cooling system pressure cap (1). Close the

cover.
SEBU7469-03 95
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

10. Check the radiator for any external leaks. Check

for air bubbles in the radiator.

11. Stop the engine.

i01830643

Cooling System Coolant

Extender (ELC) - Add
SMCS Code: 1352-045; 1352-535; 1352-544;
1352-544-NL; 1395-081

g00934396
Illustration 110

Personal injury can result from hot coolant, steam 2. Open the cover. Remove cooling system pressure
and alkali. cap (1) slowly in order to relieve the pressure.
At operating temperature, engine coolant is hot 3. Drain some coolant from the radiator into a
and under pressure. The radiator and all lines suitable container. This will allow space for
to heaters or the engine contain hot coolant or additional cooling system coolant extender.
steam. Any contact can cause severe burns.
4. In order to add cooling system coolant extender,
Remove cooling system pressure cap slowly to refer to the Special Publication, SEBU6250,
relieve pressure only when engine is stopped and “Extended Life Coolant (ELC)”. Refer to the table
cooling system pressure cap is cool enough to for the correct amount of Caterpillar Extended
touch with your bare hand. Life Coolant (ELC) Extender that is needed to be
added to the cooling system.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing 5. Install cooling system pressure cap (1). Close the
burns. cover.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

When a Caterpillar Extended Life Coolant (ELC)

is used, an extender must be added to the cooling
system. See the Operation and Maintenance
Manual, “Maintenance Interval Schedule” for the
proper service interval. The amount of extender is
determined by the cooling system capacity.

1. Stop the engine and allow the engine to cool.

96 SEBU7469-03
Maintenance Section
Cooling System Coolant Level - Check

i01889958

Cooling System Coolant Level

- Check
SMCS Code: 1350-040-HX; 1350-040; 1350-535;
1350-535-FLV; 1353-535-FLV; 1354-535;
1395-082; 1395-535-FLV; 1395-535

Personal injury can result from hot coolant, steam

and alkali.
g00936997
At operating temperature, engine coolant is hot Illustration 112
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or 2. If necessary, add the appropriate coolant mixture.
steam. Any contact can cause severe burns. Open the cover. Remove filler cap (2) slowly in
order to relieve pressure. Add coolant through the
Remove filler cap slowly to relieve pressure only filler tube.
when engine is stopped and radiator cap is cool
enough to touch with your bare hand. 3. Install filler cap (2). Close the cover.

Do not attempt to tighten hose connections when

i01834310
the coolant is hot, the hose can come off causing
burns. Cooling System Pressure Cap
Cooling System Conditioner contains alkali. Avoid - Clean/Replace
contact with skin and eyes.
SMCS Code: 1382-070; 1382-510
The sight gauge for the cooling system is located on
the left side of the machine at the rear of the machine.
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.

Remove filler cap slowly to relieve pressure only

when engine is stopped and radiator cap is cool
enough to touch with your bare hand.

Do not attempt to tighten hose connections when

the coolant is hot, the hose can come off causing
g00934460
Illustration 111 burns.

1. Maintain coolant level so that coolant is visible in Cooling System Conditioner contains alkali. Avoid
sight gauge (1). contact with skin and eyes.

Cooling system pressure cap (1) is positioned in the

left rear of the hood.
SEBU7469-03 97
Maintenance Section
Cooling System Water Temperature Regulator - Replace

Replace the cooling system water temperature

regulator on a regular basis in order to reduce the
chance of unscheduled downtime and of problems
with the cooling system.

The water temperature regulator should be replaced

after the cooling system has been cleaned. Replace
the water temperature regulator while the cooling
system is completely drained or while the cooling
system coolant is drained to a level that is below the
water temperature regulator housing assembly.

NOTICE
Failure to replace the engine’s water temperature reg-
Illustration 113
g00934396 ulator on a regularly scheduled basis could cause se-
vere engine damage.
1. Open the cover. Remove pressure cap (1) slowly
in order to relieve pressure. Note: If you are only replacing the water temperature
regulator, drain the cooling system coolant to a level
2. Inspect the cap and the cap seal for damage, that is below the water temperature regulator housing
deposits, and foreign material. Clean the cap assembly.
with a clean cloth. Replace the cap if the cap is
damaged. 1. Loosen the hose clamp and remove the hose from
the water temperature regulator housing.
3. Install the cap. Close the cover.
2. Remove the bolts from the water temperature
i00350379 regulator housing and remove the water
temperature regulator housing.
Cooling System Water
3. Remove the gasket and remove the water
Temperature Regulator - temperature regulator from the water temperature
Replace regulator housing.

SMCS Code: 1355-070; 1355-510; 1393-010 NOTICE

Former water temperature regulators may be used, if
they meet test specifications and are not damaged or
have excessive buildup or deposits.
Personal injury can result from hot coolant, steam
and alkali.
NOTICE
At operating temperature, engine coolant is hot Since Caterpillar engines incorporate a shunt design
and under pressure. The radiator and all lines cooling system, it is mandatory to always operate the
to heaters or the engine contain hot coolant or engine with a water temperature regulator.
steam. Any contact can cause severe burns.
Depending on load, failure to operate with a water
Remove filler cap slowly to relieve pressure only temperature regulator could result in either an over-
when engine is stopped and radiator cap is cool heating or an overcooling condition.
enough to touch with your bare hand.
NOTICE
Do not attempt to tighten hose connections when If the water temperature regulator is installed incor-
the coolant is hot, the hose can come off causing rectly, it will cause the engine to overheat.
burns.

Cooling System Conditioner contains alkali. Avoid 4. Install a new water temperature regulator and
contact with skin and eyes. a new gasket. Install the water temperature
regulator housing.

5. Install the water temperature regulator housing

and the hose. Tighten the hose clamp.
98 SEBU7469-03
Maintenance Section
Crankshaft Vibration Damper - Inspect

6. Add the cooling system coolant. Maintain the • The S·O·S analysis detected a worn crankshaft
coolant level within 13 mm (.5 inch) of the bottom front bearing.
of the filler tube.
• The S·O·S analysis detected a large amount of
gear train wear that is not caused by a lack of oil.
i01547904

Crankshaft Vibration Damper • Fluid leakage is detected during inspection.

- Inspect • The housing is damaged.
SMCS Code: 1205-040 Refer to Disassembly and Assembly, “Damper &
Crankshaft Pulley” for the procedure to remove the
Damage to the vibration damper or failure of the damper and the procedure to install the damper.
vibration damper will increase torsional vibrations.
These vibrations will result in damage to the The vibration damper can be used again if none of
crankshaft and to the other engine components. A the above conditions are found or if the vibration
deteriorating vibration damper will cause excessive damper is not damaged.
gear train noise at variable points in the speed range.
Note: Contact your Caterpillar dealer for further
information.

i01569254

Cutting Edges and End Bits -

Inspect/Replace
SMCS Code: 6801-040; 6801-510; 6804-040;
6804-510

Personal injury or death can result from the blade

falling.

Block the blade before changing blade tips.

g00811262
Illustration 115
g00807816
Illustration 114
End bits (1) and/or cutting edges (2) may be
Caterpillar recommends replacing vibration damper damaged. End bits (1) and/or cutting edges (2) may
(1) for any of the following reasons: be worn excessively. Replace the end bits (1) and/or
the cutting edges (2), as needed.
• The engine has had a failure because of a broken
crankshaft.
SEBU7469-03 99
Maintenance Section
Drawbar Ball and Socket - Lubricate

1. Place blocks under the blade. Lower the blade i02528988

onto the blocks. Do not block up the blade too
high. Just use enough blocks so that end bits (1) Drawbar Ball and Socket End
and cutting edges (2) can be removed. Play - Check/Adjust
2. Remove end bits (1) and/or cutting edges (2). SMCS Code: 6170-025; 6170-535; 6171-025;
6171-535
3. Install new end bits (1) and/or new cutting edges
(2).
Check
4. Raise the blade and remove the blocks.
Rotate the blade so that the blade is placed at an
angle of 90 degrees to the frame. Lower the blade to
i02528905 the ground. While you maintain a light load between
the ball and the socket, inch the machine slowly to
Drawbar Ball and Socket - the rear. Stop the machine and shut off the engine.
Lubricate
SMCS Code: 6170-086; 6171-086

Note: Caterpillar recommends the use of 5%

molybdenum grease for lubricating the drawbar ball
and socket. Refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for
more information on molybdenum grease.

Wipe the fitting before you apply lubricant through

the fitting.

g01265355
Illustration 117

Measure the end play that is between ball (2) and

cap (3). The end play should be 0.6 ± 0.2 mm
(.02 ± .01 inch). Adjust the end play, if necessary.

Adjust
1. Support the drawbar and support the circle.

2. Remove bolts (1) that hold the drawbar to the

g00949567
bolster. Move the drawbar backward or move the
Illustration 116 machine forward.
Apply the appropriate lubricant through the fitting in
order to lubricate the drawbar ball and socket.

g01265363
Illustration 118
100 SEBU7469-03
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace

3. Remove capscrews (7) from cap (3) that holds the 3. Remove primary filter element (2) from the air
drawbar and adapter (6) together. Remove the filter housing.
adapter.
4. Clean the inside of the air filter housing.
4. As required, remove shims (4) or install shims
(4) in order to attain an end play of 0.6 ± 0.2 mm 5. If the machine is equipped with a vacuator valve,
(.02 ± .01 inch). clean the vacuator valve on the cover for the air
filter housing.
5. Install capscrews (7) in cap (3) and adapter (6).
Rotate cap (3) by hand. The socket should rotate 6. Install a clean primary air filter element. Install the
freely on ball (2). cover for the air filter housing.

6. Check the torque on bolts (5) that hold ball (2) Note: Refer to “Cleaning Primary Air Filter Elements”.
in place. The correct torque is 500 ± 65 N·m
(370 ± 50 lb ft). 7. Reset the engine air filter service indicator.

7. Assemble the drawbar to the bolster. Tighten bolts 8. Close the access door.
(1) to a torque of 950 ± 50 N·m (701 ± 37 lb ft).
If the yellow piston in the indicator moves into the red
zone after starting the engine or the exhaust smoke
i01631934
is still black after installation of a clean primary filter
Engine Air Filter Primary element, install a new primary filter element. If the
piston remains in the red zone replace the secondary
Element - Clean/Replace element.

SMCS Code: 1051-070-PY; 1051-510-PY;

1054-070-PY; 1054-510-PY
Cleaning Primary Air Filter
Elements
NOTICE
Service the air cleaner only with the engine stopped. NOTICE
Engine damage could result. Caterpillar recommends certified air filter cleaning ser-
vices available at participating Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
Service the air cleaner filter element when the to assure consistent quality and sufficient filter life.
yellow piston on the engine air filter service
indicator enters the red zone or the indicator Observe the following guidelines if you attempt to
reads 63.5 cm (25 inch) of water. Refer to clean the filter element:
Operation and Maintenance Manual, “Engine Air
Filter Service Indicator - Inspect”. Do not tap or strike the filter element in order to re-
move dust.
1. Open the access door for the air filter housing.
Refer to Operation and Maintenance Manual, Do not wash the filter element.
“Access Doors and Covers”.
Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.

Do not use air filters with damaged pleats, gaskets, or

seals. Dirt entering the engine will cause damage to
engine components.

The primary air filter element can be used up to

six times if the element is properly cleaned and
inspected. When the primary air filter element is
g00102316
Illustration 119 cleaned, check for rips or tears in the filter material.
The primary air filter element should be replaced at
2. Remove cover (1) for the air filter housing . least one time per year. This replacement should be
performed regardless of the number of cleanings.
SEBU7469-03 101
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace

Vacuum Cleaning
NOTICE
Do not clean the air filter elements by bumping or tap- Vacuum cleaning is another method for cleaning
ping. This could damage the seals. Do not use ele- primary air filter elements which require daily cleaning
ments with damaged pleats, gaskets, or seals. Dam- because of a dry, dusty environment. Cleaning with
aged elements will allow dirt to pass through. Engine pressurized air is recommended prior to vacuum
damage could result. cleaning. Vacuum cleaning will not remove deposits
of carbon and oil.
Visually inspect the primary air filter elements before
cleaning. Inspect the air filter elements for damage Inspecting the Primary Air Filter
to the seal, the gaskets, and the outer cover. Discard Elements
any damaged air filter elements.

There are two common methods that are used to

clean primary air filter elements:

• Pressurized air
• Vacuum cleaning

Pressurized Air
Pressurized air can be used to clean primary air filter
elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum g00281693
Illustration 121
pressure of 207 kPa (30 psi).
Inspect the clean, dry primary air filter element. Use
a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air filter
element. Rotate the primary air filter element. Inspect
the primary air filter element for tears and/or holes.
Inspect the primary air filter element for light that may
show through the filter material. If it is necessary in
order to confirm the result, compare the primary air
filter element to a new primary air filter element that
has the same part number.

Do not use a primary air filter element that has any

tears and/or holes in the filter material. Do not use
a primary air filter element with damaged pleats,
Illustration 120
g00281692 gaskets or seals. Discard damaged primary air filter
elements.
Note: When the primary air filter elements are
cleaned, always begin with the clean side (inside) Storing Primary Air Filter Elements
in order to force dirt particles toward the dirty side
(outside). If a primary air filter element that passes inspection
will not be used, the primary air filter element can
Aim the hose so that the air flows inside the element be stored for future use.
along the length of the filter in order to help prevent
damage to the paper pleats. Do not aim the stream of
air directly at the primary air filter element. Dirt could
be forced further into the pleats.
102 SEBU7469-03
Maintenance Section
Engine Air Filter Secondary Element - Replace

1. Open the access door on the left side of the

engine compartment. Remove the air cleaner
cover and the primary element.

g00281694
Illustration 122

Do not use paint, a waterproof cover, or plastic as a

protective covering for storage. An airflow restriction Illustration 123
g00039214
may result. To protect against dirt and damage, wrap
the primary air filter elements in Volatile Corrosion 2. Remove the secondary element.
Inhibited (VCI) paper.
3. Cover the air inlet opening. Clean the inside of
Place the primary air filter element into a box for the air cleaner housing.
storage. For identification, mark the outside of the
box and mark the primary air filter element. Include 4. Uncover the air inlet opening. Install a new
the following information: secondary element.

• Date of cleaning 5. Install the primary element and the air cleaner
cover.
• Number of cleanings
6. Close the left side engine compartment door.
Store the box in a dry location.
Note: When you replace the air filter element, you
i01562943
must replace the filter screen. Refer to Operation
and Maintenance Manual, “Engine Air Filter Service
Engine Air Filter Secondary Indicator Screen - Check/Replace”.
Element - Replace
i01567539
SMCS Code: 1051-510-SE; 1054-510-SE
Engine Air Filter Service
NOTICE Indicator - Inspect
Always replace the secondary element. Do not at-
tempt to reuse it by cleaning. Engine damage could SMCS Code: 7452-040; 7452-040-DJ;
result. 7452-040-ENG

Refer to the Operation and Maintenance Manual,

Refer to the Operation and Maintenance Manual, “Access Doors and Covers” for the location of the
“Access Doors and Covers” for the location of the
service points.
service points.

Note: Replace the engine air filter secondary element

when you service the engine air filter primary element
for the third time. Replace the secondary element
if the exhaust smoke remains black and a clean
primary element has been installed. Also, replace
the secondary element if the element has been in
service for one year.
SEBU7469-03 103
Maintenance Section
Engine Air Filter Service Indicator - Inspect/Replace

g00814560 g00814560
Illustration 124 Illustration 125

1. Start the engine. 2. Stop the engine. Check the operation of the
service indicator by pressing the reset button on
2. Run the engine at high idle. the bottom of the service indicator. This should
require three pushes or less of the reset button.
3. Open the left side engine compartment door.
3. Next, check the movement of the yellow piston
4. If the yellow piston in the engine air filter service in the service indicator. Start the engine and
indicator enters the red zone, service the air accelerate the engine to high idle for a few
cleaner. seconds. After the accelerator control (pedal)
is released, the yellow piston should remain at
5. Stop the engine. the highest position that was achieved during
acceleration.
Note: See the Operation and Maintenance Manual,
“Engine Air Filter Primary Element - Clean/Replace”. Note: The air filter indicator should be replaced
See the Operation and Maintenance Manual, “Engine during engine overhauls. The air filter indicator should
Air Filter Secondary Element - Replace”. also be replaced during replacement of any major
engine component . Replace the air filter indicator at
Note: Refer to Operation and Maintenance Manual, least one time per year.
“Engine Air Filter Service Indicator - Inspect/Replace”
in order to check an engine air filter service indicator 4. If the indicator will not reset easily, replace the
that is faulty. service indicator. If the yellow piston of the
indicator will not latch at the highest vacuum that is
attained, replace the service indicator. Tighten the
i01563032
indicator to a torque of 2 N·m (18 lb in). Excessive
Engine Air Filter Service tightening force may crack the top of the indicator.
For more information on the air filter indicator,
Indicator - Inspect/Replace refer to Video Tape, PEVN1736, “Caterpillar Air
Filter Service Indicator”.
SMCS Code: 7452-040; 7452-510
Note: If you still believe that the service indicator
Refer to the Operation and Maintenance Manual, is working improperly, refer to Operation and
“Access Doors and Covers” for the location of the Maintenance Manual, “Engine Air Filter Service
service points. Indicator Screen - Check/Replace”.

1. Open the access door. 5. Close the left side engine compartment door.
104 SEBU7469-03
Maintenance Section
Engine Air Filter Service Indicator Screen - Check/Replace

i01507598 Replace
Engine Air Filter Service 1. Remove the air cleaner from the air cleaner
Indicator Screen - housing. Removing the air cleaner from the air
cleaner housing will provide access to the hole
Check/Replace inside the tube assembly. Filter screen (1) is
installed inside the tube assembly.
SMCS Code: 7452-510-Z3; 7452-535-Z3
2. A 50.8 mm (2.00 inch) piece of 3.18 mm
(0.125 inch) drill rod is needed in order to push
filter screen (1) from the inside of the tube
assembly to the outside.

3. After the plugged filter screen (1) has been

removed, install a new filter screen (1) in the hole
on the outside of the tube assembly. Use a piece
of 6.4 mm (0.25 inch) drill rod to lightly seat the
filter element in the bottom of the bore.

i01550089

Engine Air Precleaner - Clean

SMCS Code: 1055-070; 1055-070-DJ

NOTICE
Service the engine air precleaner only with the engine
stopped. Engine damage could result.
g00782634
Illustration 126
Typical Example The engine air precleaner is positioned on top of the
engine compartment.
Check
Refer to the Operation and Maintenance Manual,
“Access Doors and Covers” for the location of the
service points.

1. Set an 8N-2694 Air Filter Service Indicator to

indicate a restricted indicator screen.

2. Screw the indicator onto a 1/8 inch NPT pipe

nipple.

3. Open the access door in order to service the

indicator screen.
g00805907
Illustration 127
4. Screw the other end of the nipple into the fitting in
the tube assembly. Normally, filter screen (1) is 1. Loosen clamp (1) at the bottom of engine air
located in the tube assembly. precleaner (2).
5. Depress the reset button on the 8N-2694 Air 2. Remove engine air precleaner (2) and inspect the
Filter Service Indicator. opening for dirt and debris. Clean the tubes, if
necessary.
6. If the indicator resets, filter screen (1) is not
plugged. If the indicator does not reset, filter 3. Clean engine air precleaner (2) with pressure air
screen (1) is plugged. Filter screen (1) should be or wash the engine air precleaner (2) in clean
replaced. warm water.

4. Install engine air precleaner (2). Tighten clamp (1).

SEBU7469-03 105
Maintenance Section
Engine Crankcase Breather - Replace

i01632265 Start the engine and check the “ENGINE

RUNNING” side of dipstick (2) while the engine is
Engine Crankcase Breather - running. Maintain the oil level between the “ADD”
Replace mark and the “FULL” mark.

SMCS Code: 1317-510 4. Remove oil filler cap (1). If necessary, add oil.

Only replace the engine crankcase breather when 5. Clean the oil filler cap and install the oil filler cap.
you rebuild the engine.
6. Close the left side engine compartment door.

i01885749
i01885827
Engine Oil Level - Check
Engine Oil Sample - Obtain
SMCS Code: 1000-535-FLV; 1302-535-FLV;
1326-535-OC; 1326-535-FLV; 1348-535-FLV SMCS Code: 1348-008; 1348-554-SM; 7542-008;
7542-554-OC, SM

Refer to the Operation and Maintenance Manual,

“Access Doors and Covers” for the location of the
Hot oil and hot components can cause personal service points.
injury. Do not allow hot oil or hot components to
contact skin.

NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.

Refer to the Operation and Maintenance Manual,

“Access Doors and Covers” for the location of the
service points.

1. Open the left side engine compartment door.

2. Clean the area around the dipstick and clean the g00978890
area around the oil filler cap before you remove Illustration 129
the dipstick and the oil filler cap.
The sampling valve for the engine oil is located on
the left side of the engine compartment.

Refer to Special Publication, SEBU6250, “Caterpillar

Machine Fluids Recommendations”, “S·O·S Oil
Analysis” for information that pertains to obtaining a
sample of the engine oil. Refer to Special Publication,
PEHP6001, “How To Take A Good Oil Sample” for
more information about obtaining a sample of the
engine oil.

g00978801
Illustration 128

3. Before you start the engine, check the “ENGINE

STOPPED” side of dipstick (2) while the engine is
stopped. Maintain the oil level between the “ADD”
mark and the “FULL” mark.
106 SEBU7469-03
Maintenance Section
Engine Oil and Filter - Change

i01885872 Abnormally harsh operating cycles or harsh

environments can shorten the service life of
Engine Oil and Filter - Change the engine oil. Arctic temperatures, corrosive
environments, or extremely dusty conditions may
SMCS Code: 1302-044-OC; 1308-510; 1318-510; require a reduction in engine oil change intervals
1326-535-OC; 1348-044 from the recommendations in Table 6. Also refer
to Special Publication, SEBU5898, “Cold Weather
Selection of the Oil Change Interval Recommendations”. Poor maintenance of air filters
or of fuel filters requires reduced oil change intervals.
See your Caterpillar dealer for more information if this
NOTICE product will experience abnormally harsh operating
This machine is equipped with an engine that meets cycles or harsh environments.
EPA Tier 2, Euro Stage II, or MOC Step 2 emission
regulations. A 500 hour engine oil change interval is Table 6
available, provided that operating conditions and rec-
H Series Emissions Motor Graders
ommended multigrade oil types are met. When these
Engine Oil Change Interval(1)
requirements are not met, shorten the oil change
interval to 250 hours, or use an S·O·S oil sampling Operating Conditions
and analysis program to determine an acceptable oil
Severe
change interval.
Multigrade High Fuel Altitude
If you select an interval for oil and filter change that is Oil Type Normal(2) Load Sulfur above
too long, you may damage the engine. Factor(3) from 1830 m
0.3% to (6000 ft)
0.5%(4)
Cat oil filters are recommended.
Cat DEO
500 hr 500 hr 500 hr 250 hr(6)
Preferred
Recommended multigrade oil types are listed in
Table 6. Do not use single grade oils. API CH-4
11.0
minimum 500 hr 500 hr 500 hr 250 hr(6)
TBN(4)
Preferred
API CH-4
TBN(4) 500 hr 500 hr 250 hr(5) 250 hr(6)
below 11.0
API CG-4 500 hr 250 hr(5) 250 hr(5) 250 hr(6)
API CF-4 250 hr(5) 250 hr(6) 250 hr(6) 250 hr(6)
(1) The traditional oil change interval for engines is 250 hours.
The standard oil change interval in this machine is 500 hours, if
the operating conditions and recommended oil types that are
listed in this table are met. Improvements in the engine allow
this engine oil change interval. This new standard interval is not
g00753767 permitted for other machines. Refer to the applicable Operation
Illustration 130 and Maintenance Manuals for the other machines.
API Trademark (2) Normal conditions include these factors: Fuel sulfur below
0.3%, altitude below 1830 m (6000 ft), and good air filter and
Commercial oils that are licensed by the American Petroleum
fuel filter maintenance. Normal conditions do not include high
Institute (API) bear this trademark. Commercial oils that do
load factor, harsh operating cycles, or harsh environments.
not bear this trademark are not licensed and these oils are (3) High load factors can shorten the service life of your engine
not recommended. Oils that are not listed in Table 6 are not
recommended. oil. Continuous heavy load cycles and very little idle time result
in increased fuel consumption and oil contamination. These
factors deplete the oil additives more rapidly. To determine
average fuel consumption, measure average fuel consumption
for a period of 50 to 100 hours. If the application of the machine
is changed, the average fuel consumption may change.
(4) For sulfur content above 0.5%, refer to Special Publication,
SEBU6250, “Total Base Number (TBN) and Fuel Sulfur Levels
for Direct Injection (DI) Diesel Engines”.
(5) In order to verify an oil change interval of 500 hours, refer to
“Program A” below.
(6) Use “Program B” below to determine an appropriate interval.
SEBU7469-03 107
Maintenance Section
Engine Oil and Filter - Change

Adjustment of the Oil Change Interval Procedure for Changing the Engine
Note: Your Caterpillar dealer has additional
Oil and Filter
information on these programs.

Program A
Hot oil and hot components can cause personal
Verification for an Oil Change Interval of 500 Hours injury. Do not allow hot oil or hot components to
contact skin.
This program consists of three oil change intervals of
500 hours. Oil sampling and analysis is done at 250
hours and 500 hours for each of the three intervals NOTICE
for a total of six oil samples. The analysis includes Care must be taken to ensure that fluids are contained
oil viscosity and infrared (IR) analysis of the oil. If during performance of inspection, maintenance, test-
all of the results are satisfactory, the 500 hour oil ing, adjusting and repair of the product. Be prepared to
change interval is acceptable for the machine in that collect the fluid with suitable containers before open-
application. Repeat Program A if you change the ing any compartment or disassembling any compo-
application of the machine. nent containing fluids.

If a sample does not pass the oil analysis, take one Refer to Special Publication, NENG2500, “Caterpillar
of these actions: Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
• Shorten the oil change interval to 250 hours. products.

• Proceed to Program B. Dispose of all fluids according to local regulations and

mandates.
• Change to a preferred oil type in Table 6.
NOTICE
Program B Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
Optimizing Oil Change Intervals

Begin with a 250 hour oil change interval. The oil Refer to the Operation and Maintenance Manual,
change intervals are adjusted by increments. Each “Access Doors and Covers” for the location of the
interval is adjusted an additional 50 hours. Periodic oil service points.
sampling and analysis is done during each interval.
The analysis includes oil viscosity and infrared (IR) Park the machine on a level surface and engage the
analysis of the oil. Repeat Program B if you change parking brake. Stop the engine.
the application of the machine.
Note: Drain the crankcase while the oil is warm. This
If an oil sample does not pass the analysis, shorten allows waste particles that are suspended in the oil to
the oil change interval, or change to a preferred drain. As the oil cools, the waste particles will settle
multigrade oil type in the listing above. to the bottom of the crankcase. The particles will not
be removed by draining the oil and the particles will
References recirculate in the engine lubrication system with the
new oil.
Reference: Special Publication, PEDP7035,
“Optimizing Oil Change Intervals” Note: Articulate the machine to the left in order to get
better access to the crankcase drain valve.
Reference: Special Publication, PEDP7036, “S·O·S
Fluid Analysis”

Reference: Special Publication, PEDP7076,

“Understanding the S·O·S Oil Analysis Tests”
108 SEBU7469-03
Maintenance Section
Engine Overheating

g00804939 g00978897
Illustration 131 Illustration 133

1. Open crankcase drain valve (1). Valve (1) is 8. Clean the area around dipstick (3) before you
located on the underside of the machine near the remove the dipstick. Clean the area around oil
rear of the machine. Allow the oil to drain into a filler cap (4) before you remove the oil filler cap.
suitable container. Remove the oil filler cap (4). Fill the crankcase
with new oil. See Operation and Maintenance
Note: Discard any drained fluids and discard any Manual, “Capacities (Refill)”. Clean the filler cap
filter elements according to local regulations. and install the filler cap.

2. Close valve (1). 9. Start the engine and allow the oil to warm. Check
the engine for leaks.
3. Open the access door for the engine compartment
on the left side of the machine. 10. Run the engine. Check the “ENGINE RUNNING”
side of dipstick (3) while the engine is running.
Maintain the oil level between the “ADD” mark and
the “FULL” mark. If necessary, add oil .

11. Stop the engine. Close the access door for

the engine compartment on the left side of the
machine.

i01900293

Engine Overheating
SMCS Code: 1000; 1350; 1353

Illustration 132
g00978895 If your machine experiences an engine overheating
problem, do the following maintenance procedures
4. Clean the area around engine oil filter (2) before in the order that is listed:
you remove the engine oil filter. Remove the
engine oil filter with a strap type wrench. See the 1. Operation and Maintenance Manual, “Cooling
Operation and Maintenance Manual, “Oil Filter - System Coolant Level − Check”
Inspect”.
2. Operation and Maintenance Manual, “Radiator -
5. Clean the base of the engine oil filter housing. Clean”
Make sure that all of the old filter gasket is
removed. 3. Operation and Maintenance Manual, “Belt -
Inspect”
6. Apply a light coat of engine oil to the gasket of the
new engine oil filter. 4. Operation and Maintenance Manual, “Cooling
System Pressure Cap - Clean/Replace”
7. Install the new engine oil filter by hand. Additionally
tighten the engine oil filter by 3/4 of a turn, after 5. Operation and Maintenance Manual, “Radiator
the gasket contacts the filter base. Core - Clean”
SEBU7469-03 109
Maintenance Section
Engine Power Loss

6. Operation and Maintenance Manual, “Cooling

System Water Temperature Regulator - Replace” NOTICE
Only qualified service personnel should perform this
If the engine overheating problem is not corrected, maintenance. Refer to the Service Manual or your
consult your Caterpillar dealer. Caterpillar dealer for the complete valve lash adjust-
ment procedure.
i01900299
Operation of Caterpillar engines with improper valve
Engine Power Loss adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
SMCS Code: 1000; 1051; 1250 and/or shortened engine component life.

If your machine experiences an engine power loss,

perform the following maintenance procedures in the NOTICE
order that is listed: Do not use the yoke that comes out of the front of the
engine in order to turn over the engine. Damage to the
1. Operation and Maintenance Manual, “Engine Air crankshaft vibration damper can occur.
Filter Service Indicator - Inspect”
The adjustment is necessary due to the initial wear of
2. Operation and Maintenance Manual, “Engine Air the valve train components and to the seating of the
Precleaner - Clean” valve train components.
3. Operation and Maintenance Manual, “Engine Air This maintenance is recommended by Caterpillar
Filter Primary Element - Clean/Replace” as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
4. Operation and Maintenance Manual, “Engine Air life.
Filter Secondary Element - Replace”
Ensure that the engine is stopped before you
5. Operation and Maintenance Manual, “Fuel Tank measure the valve lash. To obtain an accurate
Water and Sediment - Drain” measurement, allow the valves to cool before you
perform this maintenance.
6. Operation and Maintenance Manual, “Fuel Tank
Cap and Strainer - Clean” Remove the cover in order to access the rear of
the engine. Check the valve lash. For the correct
7. Operation and Maintenance Manual, “Fuel System adjustment procedure, refer to Systems Operation,
Water Separator Element - Replace” Testing and Adjusting, “Engine Valve Lash -
Inspect/Adjust”.
8. Operation and Maintenance Manual, “Fuel System
Secondary Filter - Replace”
i00128925
If the power loss is not corrected, consult your
Caterpillar dealer. Engine Valve Rotators - Inspect
SMCS Code: 1109-040
i01498587

Engine Valve Lash - Check

SMCS Code: 1105-535 When inspecting the valve rotators, protective
glasses or face shield and protective clothing
must be worn, to prevent being burned by hot oil
spray.
Ensure that the engine can not be started while
this maintenance is being performed. To help pre- Inspect the engine valve rotators after the valve
vent possible injury, do not use the starting motor clearances have been set.
to turn the flywheel.
1. Start the engine and run the engine at low idle.
Hot engine components can cause burns. Allow
additional time for the engine to cool before mea- 2. Watch the top surface of each valve rotator. When
suring/adjusting valve lash clearance. the intake valve or the exhaust valve closes, the
engine valve rotator should turn slightly.
110 SEBU7469-03
Maintenance Section
Evaporator Coil and Heater Coil - Clean

If an intake valve or an exhaust valve fails to rotate, i01896201

consult your Caterpillar Dealer.
Final Drive Preload - Check
i01827363 SMCS Code: 4050-535-ZP
Evaporator Coil and Heater Table 7
Coil - Clean Required Tools
Part Number Description Quantity
SMCS Code: 7309-070; 7343-070
5P-4204 Wrench 1
The evaporator coil and the heater coil are located
Torque Wrench Gp
under the seat in the cab. 9U-5015 1
(3/4 Inch Drive)
1. Remove the seat.
Table 8
2. Remove both of the covers. Bearing Preload for the Final Drive
Sales Model Final Torque
12H 136 N·m (100 lb ft)

1. Park the machine on a level surface.

2. Refer to the Operation and Maintenance Manual,

“Jacking Locations” for the proper lifting points.
Support the machine so that the rear tires are
off the ground. The machine must be in a stable
position in order to be able to turn the rear tires.

3. Unlock the differential.

4. Stop the engine.

5. Drain the oil below the level of the outer cover.

g00931904
Illustration 134

3. Clean evaporator coil (1) and clean heater coil (2).

Replace both coils.

4. Replace both of the covers and replace the seat.

Note: If you are operating the machine under harsh

conditions or with the cab door open, it may be
necessary to clean the coils more often.
g00949715
Illustration 135

6. Remove outer cover (1).

SEBU7469-03 111
Maintenance Section
Fuel System - Fill

i02573704

Fuel System - Fill

SMCS Code: 1250-544

Personal injury or death may result from failure to

adhere to the following procedures.

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire.

g00949716 Clean up all leaked or spilled fuel. Do not smoke

Illustration 136
while working on the fuel system.
7. Remove lock (2).
Turn the disconnect switch OFF or disconnect the
battery when changing fuel filters.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the machine. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.

Dispose of all fluids according to local regulations and

mandates.

Illustration 137
g00985487 Reference: See Operation and Maintenance Manual,
“Capacities (Refill)” for the capacity of the fuel tank
8. Install wrench (A) to the torque wrench. Refer to for your machine.
Table 7.
Refer to Operation and Maintenance Manual,
9. Check the torque. Refer to Table 8. “Access Doors and Covers” for the location of the
service points.
10. If the torque is incorrect, refer to the adjustment
procedure in Systems Operation,Testing and
Adjusting, “Final Drive”for the Power Train System.

g00933829
Illustration 138

1. Clean filler cap (1) and the surrounding area.

2. Remove filler cap (1).

3. Fill fuel tank (2) with fuel.

112 SEBU7469-03
Maintenance Section
Fuel System - Prime

4. Install filler cap (1). i01893590

Note: Prime the fuel system. See Operation and Fuel System - Prime
Maintenance Manual, “Fuel System - Prime” for more
information. SMCS Code: 1250-548; 1258-548

Machines that are Equipped with a NOTICE

Care must be taken to ensure that fluids are contained
Fast Fill Fuel Arrangement during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
NOTICE collect the fluid with suitable containers before open-
Use only a Caterpillar approved fast fill system to fuel ing any compartment or disassembling any compo-
machines. Over pressurization may cause tank defor- nent containing fluids.
mation and fuel spillage.
Refer to Special Publication, NENG2500, “Caterpillar
Contact your Cat dealer for fast fill system availability. Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

The fuel system is primed in order to fill the fuel filter.

The fuel system is also primed in order to purge
trapped air.

Refer to the Operation and Maintenance Manual,

“Access Doors and Covers” for the location of the
service points.

The fuel priming pump is located on the top of the

Illustration 139
g01288825 water separator on the right side of the machine. The
Typical example
fuel priming is automatically controlled by the engine
ECM.
1. Park the machine on a level surface.

2. Remove dust cover (3), if equipped.

Note: The maximum fuel flow rate for the fast fill fuel
arrangement is 375 L/min (100 US gpm).

3. Fill the fuel tank through the fast fill fuel adapter.

Note: Prime the fuel system. See Operation and

Maintenance Manual, “Fuel System - Prime” for more
information.

g00985628
Illustration 140
(1) Drain valve (outlet)
(2) Drain valve (inlet)

1.

2. Open drain valve (2). Allow the fuel to drain into a

suitable container.
SEBU7469-03 113
Maintenance Section
Fuel System Secondary Filter - Replace

3. Turn the start switch key to the ON position. Keep

the start switch key in the ON position until a
steady flow of fuel comes out of the drain hose.
Then, close the drain valve.

4. Open drain valve (1). Allow the fuel to drain into a

suitable container.

5. Turn the start switch key to the ON position in

order to fill the filter element with fuel. Keep the
start switch key in the ON position until a steady
flow of fuel comes out of the drain hose. Then,
close the drain valve.

Note: The fuel system should be primed within two g00978950

minutes. If the time was more than two minutes, Illustration 141
change the filter element and repeat the priming
procedures. 1. Remove fuel filter (1).

6. Start the engine. If the engine starts but the engine 2. Drain the fuel from the fuel filter into a suitable
runs rough, allow the engine to run at low idle. container.
Continue to run the engine at low idle until the
engine runs smoothly. Note: Discard any drained fluids according to local
regulations.
7. Stop the engine.
3. Clean the mounting base for the fuel filter. Make
sure that you removed all of the old seal.
i01886154
4. Coat the seal of the new fuel filter with clean
Fuel System Secondary Filter - diesel fuel.
Replace
5. Install the new fuel filter by hand. Tighten the new
SMCS Code: 1261-510-SE fuel filter until the seal contacts the mounting base.
Then tighten the new fuel filter by an additional
3/4 of a turn.
NOTICE
Do not fill fuel filters with fuel before installing them.
Use the rotation index marks on the new fuel filter
Contaminated fuel will cause accelerated wear to fuel
as a guide for tightening the filter. These rotation
system parts.
index marks are spaced at intervals of 1/4 turn.

NOTICE 6. Close the access door for the engine compartment

Care must be taken to ensure that fluids are contained on the left side of the machine.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to i01886293
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- Fuel System Water Separator
nent containing fluids.
- Drain
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies SMCS Code: 1263-543
suitable to collect and contain fluids on Caterpillar
products. Refer to the Operation and Maintenance Manual,
“Access Doors and Covers” for the location of the
Dispose of all fluids according to local regulations and service points.
mandates.

Refer to the Operation and Maintenance Manual,

“Access Doors and Covers” for the location of the
service points.
114 SEBU7469-03
Maintenance Section
Fuel System Water Separator Element - Replace

NOTICE NOTICE
Care must be taken to ensure that fluids are contained Do not fill fuel filters with fuel before installing them.
during performance of inspection, maintenance, test- Contaminated fuel will cause accelerated wear to fuel
ing, adjusting and repair of the product. Be prepared to system parts.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids. NOTICE
Care must be taken to ensure that fluids are contained
Refer to Special Publication, NENG2500, “Caterpillar during performance of inspection, maintenance, test-
Tools and Shop Products Guide” for tools and supplies ing, adjusting and repair of the product. Be prepared to
suitable to collect and contain fluids on Caterpillar collect the fluid with suitable containers before open-
products. ing any compartment or disassembling any compo-
nent containing fluids.
Dispose of all fluids according to local regulations and
mandates. Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

Refer to the Operation and Maintenance Manual,

“Access Doors and Covers” for the location of the
service points.

g00981169
Illustration 142

1. Open drain (1) and allow the water and sediment

to drain into a suitable container.

2. Close drain (1).

3. Close the engine access door on the left side of

the machine.
g00981190
Illustration 143
i01886292

Fuel System Water Separator 1. In order to drain filter (2), open drain valve (3) on
water separator bowl (1). The water separator
Element - Replace bowl is under filter (2). Catch the fuel in a suitable
container.
SMCS Code: 1263-510-FQ
Note: Discard any drained fluids according to local
regulations.

Fuel leaked or spilled onto hot surfaces or electri- 2. Remove filter (2) and water separator bowl (1).
cal components can cause a fire.
3. Remove water separator bowl (1) from filter
Turn the disconnect switch OFF when draining element (2).
and/or removing any fuel system components.
4. Wash water separator bowl (1) in a clean
nonflammable solvent. Use pressure air to dry
water separator bowl (1).
SEBU7469-03 115
Maintenance Section
Fuel Tank Cap and Strainer - Clean

5. Install the clean water separator bowl onto a new i01830349

filter element.
Fuel Tank Water and Sediment
6. Clean the filter housing base. - Drain
7. Coat the seal of the new filter element with clean SMCS Code: 1273-543-M&S
diesel fuel.

8. Install the filter element onto the filter housing.

9. Close the engine access door.

i01863218

Fuel Tank Cap and Strainer -

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

Refer to the Operation and Maintenance Manual,

“Access Doors and Covers” for the location of the g00934388
Illustration 145
service points.
Drain valve (1) is located under the rear frame on the
left side of the machine.

1. Open drain valve (1). Drain the water and

sediment into a suitable container.

Note: Discard any drained fluids according to local

regulations.

2. Close the drain valve.

Note: If you need to flush the fuel sump, use drain

valve (2) that is located under the rear frame on the
right side of the machine.
g00949816
Illustration 144
i01886304
1. Remove fuel tank cap (1) and disassemble the
fuel tank cap. Fuses - Replace
2. Inspect the seal on the fuel tank cap for damage. SMCS Code: 1417-510
If the seal is damaged, replace the seal. Lubricate
the seal on the fuel tank cap. Fuses – Fuses protect the electrical system from
damage that is caused by overloaded circuits.
3. Replace the elements on the fuel tank cap. Replace the fuse if the element is separated. Check
the circuit if the element is separated in a new fuse.
4. Remove the strainer from the filler opening. Repair the circuit.

5. Wash the strainer in clean nonflammable solvent. NOTICE

Replace the fuses with the same type and size only.
6. Install the strainer.
If it is necessary to replace fuses frequently, an electri-
7. Install fuel tank cap (1). cal problem may exist. Consult your Caterpillar dealer.
116 SEBU7469-03
Maintenance Section
Fuses - Replace

Secondary Steering (Test) (5) – 10 amp

Key Switch (6) – 10 amp

Auxiliary Power Port (7) – 10 amp

Horn (8) – 10 amp

g00935115
Illustration 146
(1) Fuse panel on the steering console (unswitched power)
(2) Fuse panel on the steering console (switched power)
Turn Signals and Hazard Lamps (9) – 10
amp

Lighter (10) – 10 amp

Communications Device (11) – 15 amp

Stop Lamps (12) – 10 amp

g00935093
Illustration 147
(3) Overhead fuse panel
Radio (13) – 10 amp
There are three fuse panels. Two fuse panels are
positioned in the base of the steering column. The
other fuse panel is near the top of the cab at the right
side of the operator. Dome Lamp (14) – 10 amp

Product Link (15) – 10 amp

g00778429
Illustration 148
Fuse panel on the steering console (unswitched power)

Tail Lights and Panel Lights (4) – 10 amp

SEBU7469-03 117
Maintenance Section
Fuses - Replace

Secondary Steering (26) – 10 amp

Beacon (27) – 10 amp

Fuel System (28) – 10 amp

g00778430
Illustration 149
Fuse panel on the steering console (switched power)

Digital Electrical Monitoring System

(16) – 10 amp

Blade Floodlights (17) – 10 amp

Rear Floodlights (18) – 10 amp

g00778432
Illustration 150
Overhead fuse panel

All Wheel Drive (19) – This space is not Front Windshield Wiper/Washer (29) –
used on this machine. 15 amp

Air Dryer (20) – 10 amp Auxiliary Backup Lamps (30) – 10 amp

Differential Lock (21) – 10 amp Rear Window Wiper and Washer (31) –
10 amp

Heating and Air Conditioning System Snow Wing Light (32) – 10 amp
(22) – 15 amp

Blade Cushion and Centershift Lock Pin Windshield Defroster (33) – 10 amp
(23) – 10 amp

Transmission Control (24) – 15 amp Moldboard Light (34) – 10 amp

Parking Brake (25) – 10 amp Rear Window Defroster (35) – 10 amp

118 SEBU7469-03
Maintenance Section
Hydraulic System Oil - Change

Exterior Heated Mirrors (36) – 10 amp

i01902074

Hydraulic System Oil - Change

SMCS Code: 5050-044; 5056-044; 5095-044

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

Note: If the hydraulic oil is not being monitored

by the Caterpillar S·O·S Oil Analysis program or
an equivalent oil sampling program, change the
hydraulic oil at every 2000 service hour interval.

g00932315
Illustration 151

Hot oil and hot components can cause personal

1. Slowly remove hydraulic oil filler cap (1).
injury. Do not allow hot oil or hot components to
contact skin.
2. Drain plug (2) is positioned in the bottom of the
hydraulic oil tank. Remove the drain plug. Drain
Operate the machine until the oil is warm. the oil into a suitable container.

Park the machine on a level surface with the front 3. Replace the filter for the hydraulic system oil. See
wheel straight ahead. Lower all attachments to the Operation and Maintenance Manual, “Hydraulic
ground. Apply a slight downward pressure to the System Oil Filter - Replace” in the Maintenance
attachments. Center the articulation of the machine Interval Schedule.
and install the frame lock pin. The frame lock pin
must move freely in the frame. Move the front wheels 4. Remove the filler screen from the filler tube in the
to vertical and install the wheel lean bolt. Engage the hydraulic oil tank. Wash the filler screen in clean
parking brake. Stop the engine. nonflammable solvent. Allow the filler screen to
dry.
The hydraulic system oil tank is positioned behind
the operator station at the center of the machine. 5. Clean the drain plug and install the drain plug.

6. Install the filler screen.

7. Fill the hydraulic system oil tank. See Operation

and Maintenance Manual, “Capacities (Refill)”.

8. Inspect the filler cap gasket. If the filler cap gasket

is damaged, replace the filler cap gasket.
SEBU7469-03 119
Maintenance Section
Hydraulic System Oil Filter - Replace

9. Install the hydraulic oil filler cap. Clean the area around the filler cap before you
remove the filler cap. Clean the area around the filter
10. Start the engine. Run the engine for a few cover before you remove the filter cover.
minutes.

11. Maintain the oil level above the “MIN” mark on

sight gauge (3). If necessary, add oil through the
filler tube.

Note: The oil must be free from bubbles. If there are

bubbles in the oil, then air is entering the hydraulic
system. Inspect the suction hoses and inspect the
clamps.

12. Stop the engine.

13. If necessary, tighten any loose clamps and tighten

any loose connections. Replace any damaged
hoses.

i01827858

Hydraulic System Oil Filter -

Replace
SMCS Code: 5056-510-FI; 5068-510

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact skin.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- Illustration 152
g00932333
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- 1. Slowly remove hydraulic oil filler cap (1) in order
ing any compartment or disassembling any compo- to relieve the tank pressure.
nent containing fluids.
2. Remove filter cover (2) from the hydraulic system
Refer to Special Publication, NENG2500, “Caterpillar oil tank.
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar 3. Inspect the seal for the cover. If necessary, replace
products. the seal.
Dispose of all fluids according to local regulations and 4. Remove the filter element and discard the filter
mandates. element.

Park the machine on a level surface with front wheels 5. Install a new filter element.
straight ahead. Lower all attachments to the ground.
Apply a slight downward pressure to the attachments. 6. Install cover (2).
Center the articulation of the machine and install the
frame lock pin. The frame lock pin must move freely 7. Maintain the hydraulic oil level above the “MIN”
in the frame. Move the front wheels to vertical and mark on sight gauge (3).
install the wheel lean bolt. Engage the parking brake.
Stop the engine. 8. Inspect the filler cap gasket. If the filler cap gasket
is damaged, replace the filler cap gasket. Install
the oil filler cap.
120 SEBU7469-03
Maintenance Section
Hydraulic System Oil Level - Check

i01827874

Hydraulic System Oil Level -

Check
SMCS Code: 5050-535-FLV; 5056-535-FLV;
5095-535-FLV; 7479-535

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact skin.

Operate the machine until the oil is warm.

Park the machine on a level surface with front wheels

straight ahead. Lower all attachments to the ground.
Apply a slight downward pressure to the attachments.
Center the articulation of the machine and install the
frame lock pin. The frame lock pin must move freely
in the frame. Move the front wheels to vertical and
install the wheel lean bolt. Engage the parking brake.
Stop the engine.

The hydraulic tank sight gauge is positioned on the

left side of the machine.

g00932336
Illustration 153

1. Maintain the oil level above the “MIN” mark on

sight gauge (1).

2. If necessary, add oil. Slowly loosen the filler cap in

order to relieve the tank pressure. Remove filler
cap (2). Add oil through the filler tube.

3. Clean the filler cap and install the filler cap.

SEBU7469-03 121
Maintenance Section
Hydraulic System Oil Sample - Obtain

i01886347 The kingpins are located to the inside of the front

wheels. Each front wheel has a kingpin. Each kingpin
Hydraulic System Oil Sample has two fittings. In order to lubricate the kingpin
- Obtain bearings, use 183-3424 Grease Cartridge to apply
lubricant to the fittings.
SMCS Code: 4129-008; 5050-008; 5056-008;
5095-008; 5095-SM i01830090

Moldboard Wear Strip -

Inspect/Adjust/Replace
SMCS Code: 6174-025; 6174-040; 6174-510

1. Rotate the blade. Position the blade at an angle of

90 degrees to the frame. Lower the blade to the
ground. Stop the engine.

g00979019
Illustration 154

The sampling valve for the hydraulic oil is located

underneath the operator’s compartment on the left
side of the machine.

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

Analysis” for information that pertains to obtaining
a sample of the hydraulic oil. Refer to Special
Publication, PEHP6001, “How To Take A Good Oil g00934204
Sample” for more information about obtaining a Illustration 156
sample of the hydraulic oil.
2. Remove the top retaining plates and the bottom
retaining plates. Visually inspect the wear strips. If
i01886332 the wear strips are worn close to the moldboard,
replace the wear strips.
Kingpin Bearings - Lubricate
3. Install shims between the moldboard rail and the
SMCS Code: 4314-086 wear strips at the location of minimum clearance.
Add shims in order to provide a clearance of
Wipe all the fittings before you apply lubricant to the 0.13 mm (0.005 inch) to 0.89 mm (0.035 inch).
fittings.
Note: The shims that are required should be divided
evenly between the upper wear strips and the lower
wear strips.

4. Install the top retaining plate and install the bottom

retaining plate.

5. Start the engine. Raise the blade, so that the

blade will clear the ground. Sideshift the blade
through the entire limit of travel. Measure the
clearance between the wear strips and the blade.
This will allow you to determine the location of the
minimum clearance.

g00979000 6. Stop the engine.

Illustration 155
122 SEBU7469-03
Maintenance Section
Oil Filter - Inspect

7. Remove the top retaining plate from the center Using an oil filter element that is not recommended
wear strip bracket. Visually inspect the wear strips. by Caterpillar can result in severe engine damage
If the wear strips are worn close to the moldboard, to engine bearings, to the crankshaft, and to other
replace the wear strips. parts. This can result in larger particles in unfiltered
oil. The particles could enter the lubricating system
8. Install shims between the moldboard rail and the and the particles could cause damage.
wear strips at the location of minimum clearance.
Add shims in order to provide a clearance of
i01863714
0.13 mm (0.005 inch) to 0.89 mm (0.035 inch).

9. Install the top retaining plate for the center wear

Parking Brake - Drain
strip bracket. SMCS Code: 4267-543-M&S

i02106227

Oil Filter - Inspect Sudden movement of the machine or release of

air under pressure can cause injury to persons on
SMCS Code: 1308-507; 3004-507; 3067-507; or near the machine. To prevent possible injury,
5068-507 perform the procedure that follows before testing
and adjusting the air system and brakes.
Inspect a Used Filter for Debris
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

Illustration 157
g00100013 mandates.
The element is shown with debris.
1. Move the machine to a smooth horizontal location.
Use a filter cutter to cut the filter element open. Move away from operating machines and move
Spread apart the pleats and inspect the element for away from personnel. Lower all implements to the
metal and for other debris. An excessive amount of ground.
debris in the filter element can indicate a possible
failure. 2. Install the wheel lean locking bolt in the front axle.
Install the frame lock pin. Engage the parking
If metals are found in the filter element, a magnet can brake and stop the engine.
be used to differentiate between ferrous metals and
nonferrous metals. 3. Permit only one operator on the machine. Keep all
other personnel away from the machine. Also, all
Ferrous metals can indicate wear on steel parts and personnel should be visible to the operator.
on cast iron parts.
4. Place chocks in front of the wheels and behind
Nonferrous metals can indicate wear on the the wheels.
aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.

Small amounts of debris may be found in the filter

element. This could be caused by friction and by
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount
of debris is found.
SEBU7469-03 123
Maintenance Section
Radiator - Clean

i01863242

Radiator - Clean
SMCS Code: 1353-070; 1805-070; 1810-070

g00950101
Illustration 158
(1) Parking brake
(2) Outer plug

1. Remove outer plug (2) and an inner plug (not

g00949836
shown) behind outer plug (2). Illustration 160

2. Start the engine. Make sure that the air system 1. Remove the access cover on the left rear of the
pressure reaches 965 ± 34 kPa (140 ± 5 psi). machine. Remove the access cover on the right
rear of the machine.

2. Remove any dirt from the area around the radiator.

Remove any debris from the area around the
radiator.

3. Install the access covers.

i01671005

Radiator Core - Clean

SMCS Code: 1353-070; 1353-070-KO

g00950104 You can use compressed air, high pressure water,

Illustration 159 or steam to remove dust and other debris from the
(3) Transmission control (lever) radiator core. However, the use of compressed air
is preferred.
3. Make sure that the service brake control (pedal)
is down. Move lever (3) from PARKING BRAKE See Special Publication, SEBD0518, “Know Your
ENGAGED position to the NEUTRAL position Cooling System” for the complete procedure for
and back to the PARKING BRAKE ENGAGED cleaning the radiator core.
position.

4. Continue to move lever (3) from PARKING BRAKE

ENGAGED position to the NEUTRAL position
and back to the PARKING BRAKE ENGAGED
position. This will drain the moisture from parking
brake (1).

5. Stop the engine and allow the air to escape from

the system. Replace the inner plug and outer plug
(2).
124 SEBU7469-03
Maintenance Section
Refrigerant Dryer - Replace

i01827882 Note: When you operate the machine in a climate

with high humidity, replace the in-line refrigerant dryer
Refrigerant Dryer - Replace after every 1000 service hours or 6 months.
SMCS Code: 7322-510
i01863759

Ripper Cylinder Bearings -

Personal injury can result from contact with refrig- Lubricate
erant.
SMCS Code: 5352-086; 6325-086
Contact with refrigerant can cause frost bite. Keep
face and hands away to help prevent injury. Wipe all the fittings before you apply lubricant to the
fittings.
Protective goggles must always be worn when re-
frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant.

Always use precaution when a fitting is removed.

Slowly loosen the fitting. If the system is still un-
der pressure, release it slowly in a well ventilated
area.

Personal injury or death can result from inhaling

refrigerant through a lit cigarette.

Inhaling air conditioner refrigerant gas through a

lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air con- g00853256
ditioner refrigerant gas, can cause bodily harm or Illustration 162
death.
The trunnion has one fitting (1) on each side. Use
Do not smoke when servicing air conditioners or 183-3424 Grease Cartridge to apply lubricant to
wherever refrigerant gas may be present. each fitting (1).

Use a certified recovery and recycling cart to prop- One fitting (2) is mounted on the rod end of the ripper
erly remove the refrigerant from the air condition- cylinder. Use 183-3424 Grease Cartridge to apply
ing system. lubricant to fitting (2).

i01563909

Ripper Tip - Inspect/Replace

SMCS Code: 6808-040; 6808-510

Personal injury or death can result from the ripper

falling.

Block the ripper before changing teeth.

g00812585
Illustration 161

The in-line refrigerant dryer is located under the cab

on the right side.

Refer to Service Manual, SENR5664, “In-Line

Refrigerant Dryer - Remove and Install” for the
replacement procedure of the in-line refrigerant dryer.
SEBU7469-03 125
Maintenance Section
Rollover Protective Structure (ROPS) - Inspect

i01831248

Rollover Protective Structure

Retainer pin, when struck with force, can fly out
and cause injury to nearby people. (ROPS) - Inspect
Make sure the area is clear of people when driving SMCS Code: 7323-040; 7325-040
retainer pins.
NOTICE
To avoid injury to your eyes, wear protective Do not attempt to straighten the ROPS structure. Do
glasses when striking a retainer pin. not repair the ROPS by welding reinforcement plates
to the structure.
Inspect the ripper tips. Replace the ripper tips if the
tips are damaged or the tips are worn excessively. If there are any cracks in the welds, in the castings, or
in any metal section of the ROPS, consult your Cater-
1. Block up the ripper to a height that is adequate for pillar dealer for repairs.
the removal of the tips.

g00935191
Illustration 164
g00110460
Illustration 163
1. There are two retaining pins for the ROPS. One
2. Drive out the retainer pin from the retainer side retaining pin is located on each side of the cab.
of the ripper tip. Remove the ripper tip and the Remove the access covers (1) from the retaining
retainer. pin locations.

3. Clean the adapter, the retainer pin, and the 2. Inspect the retaining pins. Inspect the keeper bolt.
retainer. Install the retainer in the groove. Replace any damaged keeper bolts or any missing
keeper bolts with only original equipment parts.
4. Install the new ripper tip over the retainer.
3. Install the access covers.
5. Drive the retainer pin through the retainer, through
the adapter, and through the ripper tip from the 4. Inspect the ROPS for any loose bolts or any
opposite side of the retainer. damaged bolts. Replace any damaged bolts or
any missing bolts with only the original equipment
6. Repeat Step 2 through Step 5 in order to replace parts. Tighten the four rear bolts (2) to a torque of
additional ripper tips. 430 ± 60 N·m (320± 45 lb ft). Tighten the nuts (3)
for the two front bolts to a torque of 240 ± 40 N·m
7. Raise the ripper. Remove the block. Lower the (180 ± 30 lb ft).
ripper to the ground.
Note: Apply oil to all ROPS bolt threads before you
install the bolts for the ROPS. Failure to apply oil can
result in improper bolt torque.

5. When you operate the machine on a rough

surface, the ROPS may rattle or the ROPS may
make a noise. If the ROPS rattles or if the ROPS
makes a noise, replace the ROPS mounting
supports .
126 SEBU7469-03
Maintenance Section
Scarifier Lift Link Socket - Lubricate

i01863262

Scarifier Lift Link Socket -

Lubricate
SMCS Code: 6162-086-LNK

Wipe all the fittings before you apply lubricant to the

fittings.

g00950158
Illustration 166

1. Block up the scarifier. Do not block up the scarifier

too high. Block up the scarifier to a height that
allows you to remove the teeth.

2. Remove the scarifier tooth from the shank.

3. Clean the shank.

g00949846
Illustration 165
4. Install the new scarifier tooth over the shank.
The machine has two fittings on each side.
5. Drive the scarifier tooth onto the shank.
In order to lubricate the scarifier lift link socket, use
6. Repeat Step 2 through Step 5 in order to replace
183-3424 Grease Cartridge (5% Molybdenum
additional scarifier teeth.
Disulfide) to apply lubricant through the fittings.
7. Raise the scarifier and remove blocking.
i01863797

Scarifier Teeth - i02429589

Inspect/Replace Seat Belt - Inspect

SMCS Code: 6807-040; 6807-510 SMCS Code: 7327-040

Always check the condition of the seat belt and the

condition of the seat belt mounting hardware before
you operate the machine. Replace any parts that are
Personal injury or death can result from the scar- damaged or worn before you operate the machine.
ifier falling.

Block the scarifier before changing the teeth.

Flying objects can cause injury or death.

Make sure the area is clear of people when remov-

ing/installing scarifier teeth.

To avoid injury to your eyes, wear protective

glasses when removing/installing scarifier teeth.

g00932801
If the scarifier teeth are damaged or worn excessively, Illustration 167
then change the scarifier teeth. Typical example
SEBU7469-03 127
Maintenance Section
Seat Belt - Replace

Check the seat belt mounting hardware (1) for wear If your machine is equipped with a seat belt
or for damage. Replace any mounting hardware that extension, also perform this replacement procedure
is worn or damaged. Make sure that the mounting for the seat belt extension.
bolts are tight.
i01886419
Check buckle (2) for wear or for damage. If the buckle
is worn or damaged, replace the seat belt. Steering Accumulator - Check
Inspect the seat belt (3) for webbing that is worn or (If Equipped)
frayed. Replace the seat belt if the seat belt is worn
or frayed. SMCS Code: 4331-535

Consult your Caterpillar dealer for the replacement of

the seat belt and the mounting hardware.

Note: Within three years of the date of installation or

within five years of the date of manufacture, replace
the seat belt. Replace the seat belt at the date which
occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.

If your machine is equipped with a seat belt

extension, also perform this inspection procedure for
the seat belt extension.
g00938287
Illustration 169
i02429594 The steering accumulator is located under the operator’s platform
on the left side of the machine.
Seat Belt - Replace
Steer the machine to the left and steer the machine
SMCS Code: 7327-510 to the right. If the movement of the steering system
is abnormal, check the nitrogen precharge. Operate
Within three years of the date of installation or within the hydraulic equipment. If the movement of the
five years of the date of manufacture, replace the steering is abnormal, check the nitrogen precharge.
seat belt . Replace the seat belt at the date which If necessary, add nitrogen. Consult your Caterpillar
occurs first. A date label for determining the age of dealer for the correct checking procedure, the correct
the seat belt is attached to the seat belt, the seat belt filling procedure and the recommended pressure.
buckle, and the seat belt retractor.

g01152685
Illustration 168
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Date of manufacture (tag) (fully extended web)
(4) Date of manufacture (underside) (buckle)

Consult your Caterpillar dealer for the replacement of

the seat belt and the mounting hardware.
128 SEBU7469-03
Maintenance Section
Tandem Breather - Clean/Replace

i02402581 Clean the surface area around the oil check plug
before you check the oil level.
Tandem Breather -
Clean/Replace
SMCS Code: 4062-070-BRE; 4062-510-BRE

g00933690
Illustration 171

1. Remove drain plug (1). Remove oil check plug (2).

Allow the oil to drain into a suitable container.
g00933727
Illustration 170
Typical example
2. When you change the tandem drive oil, use diesel
fuel in order to clean the housing of the sludge
Note: The tandem breather for your machine may be and flush the housing of the sludge.
located closer to the front of the tandem housing.
3. Clean the drain plug (1) and install the drain plug
1. Remove breathers (1) from both tandems. (1).

2. Wash breathers (1) in clean, nonflammable 4. Open the cover on the top of the tandem drive
solvent. housing. Fill the tandem drive housing with new
oil. See Operation and Maintenance Manual,
3. Use pressure air to dry breathers (1). “Capacities (Refill)”.

4. Install breathers (1) in both tandems. 5. Close the cover on the top of the tandem drive
housing.
Note: Replace breathers (1) if the breathers are
damaged. 6. Clean the oil check plug (2) and install the oil
check plug (2).

i01829602 7. Start the engine. Operate the machine for a few

minutes. Check the tandem drive housing for
Tandem Drive Oil - Change leaks.
SMCS Code: 4071-510 8. Stop the engine. Remove the oil check plug (2).
Check the oil level. Maintain the oil level to the
NOTICE bottom of the opening for the oil check plug (2). If
Care must be taken to ensure that fluids are contained necessary, add oil. Install the oil check plug (2).
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to 9. Repeat Step 1 through Step 8 for the other side.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
i01829619
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Tandem Drive Oil Level - Check
Tools and Shop Products Guide” for tools and supplies SMCS Code: 4071-535
suitable to collect and contain fluids on Caterpillar
products. Clean the surface area around the oil check plug
before you check the oil level.
Dispose of all fluids according to local regulations and
mandates.
SEBU7469-03 129
Maintenance Section
Tandem Drive Oil Sample - Obtain

i00149440

Tire Inflation - Check

SMCS Code: 4203-535-AI; 4203-535-PX

g00933714
Illustration 172

1. Remove the oil check plug.

2. Maintain the oil level at the bottom of the opening

g00103147
for the oil check plug. If necessary, add oil. Open Illustration 174
the cover on the top of the tandem drive housing
and add oil. Close the cover on the top of the Measure the air pressure on each tire. Consult your
tandem drive housing. tire dealer for the correct load rating and for the
correct operating pressures.
3. Install the oil check plug.
If necessary, inflate the tires. Refer to the following
additional information about tire inflation:
i01958878

Tandem Drive Oil Sample - • Operation and Maintenance Manual, “Tire Inflation
with Nitrogen”
Obtain
• Operation and Maintenance Manual, “Tire Shipping
SMCS Code: 4071-008 Pressure”

• Operation and Maintenance Manual, “Tire Inflation

Pressure Adjustment”

i01896071

Transmission and Differential

Oil - Change
SMCS Code: 3080-510; 3258-510-OC

Illustration 173
g00933718 Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
The oil sample for the tandem drive should be taken contact skin.
from the housing by removing one of the plates that
are located on the top of the tandem housing.

Refer to Special Publication, SEBU6250, “Caterpillar

Machine Fluids Recommendations”, “S·O·S Oil
Analysis” for information that pertains to obtaining
a sample of the tandem drive oil. Refer to Special
Publication, PEHP6001, “How To Take A Good Oil
Sample” for more information about obtaining a
sample of the tandem drive oil.
130 SEBU7469-03
Maintenance Section
Transmission and Differential Oil - Change

Note: Discard any drained fluids according to local

NOTICE regulations.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- 2. Change the filter element and clean the screens.
ing, adjusting and repair of the product. Be prepared to See the Operation and Maintenance Manual,
collect the fluid with suitable containers before open- “Transmission and Differential Oil Filter and
ing any compartment or disassembling any compo- Screen”.
nent containing fluids.
3. Clean the drain plug and install the drain plug for
Refer to Special Publication, NENG2500, “Caterpillar the differential and transmission case.
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar 4. Open the access door.
products.

Dispose of all fluids according to local regulations and

mandates.

Refer to the Operation and Maintenance Manual,

“Access Doors and Covers” for the location of the
service points.

Clean the area around the drain plug for the

differential and the transmission before you remove
the drain plug. Clean the area around the dipstick/fill
cap before you remove the dipstick/fill cap.

Operate the engine until the transmission and Illustration 176

g00986423
differential oil is warm. Park the machine on a level
surface and engage the parking brake. Lower the 5. Fill the transmission and differential case with oil
blade and apply slight down pressure to the blade. through dipstick/fill cap (2). See the Operation and
Stop the engine. Maintenance Manual, “Capacities (Refill)”.
Note: Drain the transmission and differential case 6. Remove transmission breather (3) and discard
while the oil is warm. This allows waste particles that transmission breather (3). Install a new
are suspended in the oil to drain. As the oil cools, the transmission breather.
waste particles will settle to the bottom of the case.
The particles will not be removed by draining the 7. Start the engine and run the engine at low
oil and the particles will recirculate in the lubrication idle. Inspect the transmission and differential
system with the new oil. components for leaks.

8. Engage the transmission modulator pedal. Slowly

operate the transmission control lever in order to
circulate the oil.

9. Put the transmission control in NEUTRAL. With

the engine at low idle, maintain the oil level
within the crosshatched area on dipstick (2). If
necessary, add oil through dipstick/fill cap (2).

10. Stop the engine.

11. Close the access cover.

g00986407
Illustration 175

1. Remove drain plug (1) for the differential and

transmission case. Drain the oil into a suitable
container.
SEBU7469-03 131
Maintenance Section
Transmission and Differential Oil Filter and Screens - Replace/Clean

i01896404

Transmission and Differential

Oil Filter and Screens -
Replace/Clean
SMCS Code: 3030-070-Z3; 3030-510-Z3;
3067-070; 3067-510; 3258-070-Z3; 3258-070-FI;
3258-510-FI; 3258-510-Z3

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact skin.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, 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

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

g00812873
Refer to the Operation and Maintenance Manual, Illustration 177
“Access Doors and Covers” for the location of the
service points. 2. Open drain valve (4) on oil filter housing (3).

1. Install the frame lock pin. 3. Loosen the pressure test port (1) or oil sample
valve (2) in order to vent oil filter housing (3).

4. Remove oil filter housing (3).

5. Remove the used element and discard the used

element.

6. Clean oil filter housing (3) with a clean

nonflammable solvent.

7. Clean the base of oil filter housing (3).

8. Insert a new filter element into filter housing (3).

9. Replace the filter housing base seal.

10. Install oil filter housing (3).

11. Close drain valve (4) on oil filter housing (3).

132 SEBU7469-03
Maintenance Section
Transmission and Differential Oil Level - Check

g00812875 g00986619
Illustration 178 Illustration 179

12. Slowly remove the cover for magnetic screen 23. Put the transmission control in NEUTRAL. With
(5). Slowly remove the cover for supplemental the engine at low idle, maintain the oil level
magnetic screen (6). Allow the oil to drain into a within the crosshatched area on dipstick (7). If
suitable container. necessary, add the oil through the filler tube .

13. Remove the magnetic screen tube assemblies. 24. Stop the engine.

14. Separate the magnets and the tube assemblies 25. Remove the frame lock pin and store the frame
from the screens. Wash the screens and the tube lock pin.
assemblies in clean nonflammable solvent. Allow
the screens to dry and allow the tube assemblies
i01896414
to dry.
Transmission and Differential
NOTICE
Do not drop or rap magnets on hard objects, or dam-
Oil Level - Check
age can result. Replace damaged magnets.
SMCS Code: 3030-535-FLV; 3080-535-FLV;
3258-535-FLV
15. Clean the magnets with a cloth or clean the
magnets with a firm brush. Allow the magnets to
dry.
Hot oil and hot components can cause personal
16. Install the magnets and tube assemblies into the injury. Do not allow hot oil or hot components to
screens. contact skin.
17. Install the screens.
Refer to Operation and Maintenance Manual,
18. Inspect the cover seals. If the cover seals are “Access Doors and Covers” for the location of the
damaged, replace the cover seals. service points.

19. Install the covers and tighten the bolts. Clean the area around the dipstick/fill cap before
removing the dipstick/fill cap. The dipstick/fill cap is
20. Start the engine. located on the left side of the engine compartment.

21. With the parking brake engaged, run the engine

at low idle in order to circulate the transmission oil.

22. Inspect all of the transmission components for

leaks.
SEBU7469-03 133
Maintenance Section
Transmission and Differential Oil Sample - Obtain

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

Analysis” for information that pertains to obtaining a
sample of the transmission and differential oil.

i01829992

Wheel Bearing Oil (Front) -

Change
SMCS Code: 4205-044; 4208-044; 4234-044;
7551-044-WHL

g00986631
Illustration 180

1. Put the transmission control in NEUTRAL. Run

the engine at low idle. Remove dipstick/fill cap (1).
Maintain the oil within the crosshatched area on
the dipstick.

2. If necessary, add oil.

3. Clean the dipstick/fill cap and install the dipstick/fill

cap.
g00934106
Illustration 182
i01863633

Transmission and Differential The front wheel bearings are located on the inner
side of each front wheel. The check/fill plugs (1) are
Oil Sample - Obtain located on the housings of each front wheel bearing.

SMCS Code: 3006-008; 3030-008; 3080-008; Clean the surface around each check/fill plug before
3258-008; 7542 you change the oil.

Refer to the Operation and Maintenance Manual,

NOTICE
“Access Doors and Covers” for the location of the
Care must be taken to ensure that fluids are contained
service points.
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

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

1. Remove check/fill plug (1).

g00950029
Illustration 181
2. Use a 1U-7683 Suction Gun in order to remove
The oil sample for the transmission and the the oil from the housing for the wheel bearing.
differential should be taken from the sampling valve
above the transmission filter. 3. Add oil to the housing for the wheel bearing until
the oil level is at the bottom of the opening for
check/fill plug (1).
134 SEBU7469-03
Maintenance Section
Wheel Bearing Oil Level (Front) - Check

4. Install check/fill plug (1).

5. Repeat Step 1 through Step 4 for the other wheel

bearing.

i01830000

Wheel Bearing Oil Level (Front)

- Check
SMCS Code: 4205-535-FLV; 4208-535-FLV;
4234-535-FLV; 7551-535-FLV

Clean the surface area around the check/fill plug g00118004

before you check the oil level. Illustration 184

Each front wheel has one fitting. In order to lubricate

the wheel lean bar bearings, use 183-3424 Grease
Cartridge to apply lubrication to the fittings.

i01674473

Wheel Lean Bearings -

Lubricate
SMCS Code: 5225-086-BD

Wipe all the fittings before you apply lubricant to the

fittings.
g00934106
Illustration 183

1. Remove check/fill plug (1).

2. Maintain the oil level to the bottom of the opening

for the check/fill plug. If necessary, add oil.

3. Install plug (1).

4. Repeat Step 1 through Step 3 for the other wheel

bearing.

i01671089

Wheel Lean Bar Bearings - Illustration 185

g00115441

Lubricate
Each front wheel has two fittings. In order to lubricate
SMCS Code: 5225-086-BD the wheel lean bearings, use 183-3424 Grease
Cartridge (5% Molybdenum Disulfide) to apply
Wipe all the fittings before you apply lubricant to the lubricant to the fittings.
fittings.
SEBU7469-03 135
Maintenance Section
Wheel Lean Cylinder Bearings - Lubricate

i01893509

Wheel Lean Cylinder Bearings

- Lubricate
SMCS Code: 5211-086-BD

Wipe all fittings before you apply lubricant to the

fittings.

g00937113
Illustration 187

2. Remove the filler cap for the windshield washer

reservoir.

3. Fill the window washer reservoir with window

washer solvent through the filler cap opening.

4. Install the filler cap.

g00985581
Illustration 186
5. Install the access cover.
Each end of the wheel lean cylinder has one fitting.
Note: The window washer nozzles can be adjusted
In order to lubricate the bearings for the wheel lean
so that the window washer solvent will be sprayed
cylinder, use 183-3424 Grease Cartridge (5%
in the desired direction.
Molybdenum Disulfide) to apply lubricant to the
fittings.
i01494015

i01834467 Window Wiper -

Window Washer Reservoir - Inspect/Replace
Fill SMCS Code: 7305-040; 7305-510
SMCS Code: 7306-544-KE

NOTICE
Use Caterpillar nonfreezing window washer solvent
or a commercially available windshield washer fluid
in order to prevent freezing of the windshield washer
system.

The windshield washer reservoir is positioned in the

seat support to the left of the operator’s seat.

1. Remove the access cover for the windshield

washer reservoir.
g00775786
Illustration 188
136 SEBU7469-03
Maintenance Section
Windows - Clean

Inspect the upper front windshield wiper blade (1).

Inspect the lower front windshield wiper blades (2).
If the machine is equipped with a wiper for the rear
window, inspect the wiper blade for the rear window
(3). If any of the wiper blades are streaking any of the
windshields, replace the wiper blade. Also, replace
the wiper blade if the wiper blade is streaking the
rear window.

i01494089

Windows - Clean
SMCS Code: 7310-070; 7340-070

g00775840
Illustration 189

Use commercially available window cleaning

solutions to clean the windows. Stand on the ground
in order to clean the outside windows, unless
handholds are available.