MAINTENANCE INTERVALS

Operation and Maintenance

Manual Excerpt

® ®
© 2010 Caterpillar
All Rights Reserved
 SEBU7474-03
February 2007

Operation and
Maintenance
Manual
120H and 135H Motor Graders
1241-Up (Machine)
CBC1-Up (Machine)
CAF1-Up (Machine)
AMX1-Up (Machine)
ALZ1-Up (Machine)
78 SEBU7474-03
Maintenance Section
Maintenance Interval Schedule

i02703160 Window Washer Reservoir - Fill .......................... 135

Window Wiper - Inspect/Replace ........................ 136
Maintenance Interval Schedule Windows - Clean ................................................. 136
SMCS Code: 1000; 7000 Every 10 Service Hours or Daily
Ensure that all safety information, warnings, and Air Tank Moisture and Sediment - Drain ............... 81
instructions are read and understood before any Backup Alarm - Test .............................................. 82
operation or any maintenance procedures are Brakes, Indicators and Gauges - Test ................... 84
performed. Circle Drive Pinion Teeth - Lubricate .................... 91
Circle Top - Lubricate ............................................ 92
The user is responsible for the performance of Cooling System Coolant Level - Check ................ 97
maintenance, including all adjustments, the use of Engine Air Filter Service Indicator - Inspect ........ 103
proper lubricants, fluids, filters, and the replacement Engine Air Precleaner - Clean ............................ 105
of components due to normal wear and aging. Failure Engine Oil Level - Check .................................... 106
to adhere to proper maintenance intervals and Fuel System Water Separator - Drain .................. 114
procedures may result in diminished performance of Seat Belt - Inspect .............................................. 127
the product and/or accelerated wear of components. Transmission and Differential Oil Level - Check .. 133

Use mileage, fuel consumption, service hours, or Initial 100 Service Hours
calendar time, WHICH EVER OCCURS FIRST,
in order to determine the maintenance intervals. Transmission and Differential Oil Filter and Screens -
Products that operate in severe operating conditions Replace/Clean .................................................. 131
may require more frequent maintenance.
Every 100 Service Hours or 2 Weeks
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be Articulation Bearings - Lubricate ........................... 81
performed. Axle Oscillation Bearings - Lubricate .................... 81
Belt - Inspect ......................................................... 82
When Required Blade Lift Cylinder Socket - Lubricate ................... 84
Cab Air Filter - Clean/Replace .............................. 86
Battery - Recycle .................................................. 82 Centershift Cylinder Socket - Lubricate ................ 87
Belt - Replace ....................................................... 83 Centershift Lock Bar - Clean/Lubricate ................. 87
Blade Lift Cylinder Socket - Check/Adjust/ Drawbar Ball and Socket - Lubricate .................. 100
Replace ............................................................... 84 Fuel Tank Water and Sediment - Drain ................ 116
Centershift Cylinder Socket - Check/Adjust/ Hydraulic System Oil Level - Check ................... 120
Replace ............................................................... 86 Kingpin Bearings - Lubricate ............................... 121
Circle Clearances - Check/Adjust ......................... 87 Ripper Cylinder Bearings - Lubricate .................. 125
Circle Drive Oil Level - Check ............................... 91 Scarifier Lift Link Socket - Lubricate ................... 126
Circuit Breakers - Reset ........................................ 92 Tandem Drive Oil Level - Check ......................... 129
Cutting Edges and End Bits - Inspect/Replace ..... 99 Tire Inflation - Check ........................................... 130
Drawbar Ball and Socket End Play - Wheel Bearing Oil Level (Front) - Check ............ 134
Check/Adjust ..................................................... 100 Wheel Lean Bar Bearings - Lubricate ................. 134
Engine Air Filter Primary Element - Clean/ Wheel Lean Bearings - Lubricate ....................... 135
Replace ............................................................. 101 Wheel Lean Cylinder Bearings - Lubricate ......... 135
Engine Air Filter Secondary Element - Replace .. 103
Engine Air Filter Service Indicator Screen - Initial 500 Service Hours (or at first oil
Check/Replace .................................................. 105 change)
Engine Crankcase Breather - Replace ............... 106
Engine Overheating ............................................ 109 Battery or Battery Cable - Inspect/Replace .......... 82
Engine Power Loss ............................................. 109 Engine Valve Lash - Check .................................. 110
Evaporator Coil and Heater Coil - Clean ............. 110
Fuel System - Fill ................................................. 112 Initial 500 Hours (for New Systems, Refilled
Fuel System - Prime ............................................ 113 Systems, and Converted Systems)
Fuses - Replace ................................................... 116
Moldboard Wear Strip - Inspect/Adjust/Replace .. 122 Cooling System Coolant Sample (Level 2) -
Oil Filter - Inspect ................................................ 122 Obtain ................................................................. 94
Radiator - Clean .................................................. 124
Radiator Core - Clean ......................................... 124 Every 500 Service Hours or 3 Months
Ripper Tip - Inspect/Replace .............................. 125
Air Dryer - Check .................................................. 80
Scarifier Lift Link Socket - Lubricate ................... 126
Braking System - Test ........................................... 85
Scarifier Teeth - Inspect/Replace ........................ 126
SEBU7474-03 79
Maintenance Section
Maintenance Interval Schedule

Cooling System Coolant Sample (Level 1) - Every 6000 Service Hours or 3 Years
Obtain ................................................................. 93
Engine Air Filter Service Indicator - Cooling System Coolant Extender (ELC) - Add .... 96
Inspect/Replace ................................................ 104
Engine Oil Sample - Obtain ................................ 106 Every 12 000 Service Hours or 6 Years
Engine Oil and Filter - Change ........................... 107
Cooling System Coolant (ELC) - Change ............. 94
Fuel System Secondary Filter - Replace ............. 113
Fuel System Water Separator Element -
Replace .............................................................. 114
Fuel Tank Cap and Strainer - Clean .................... 115
Hydraulic System Oil Filter - Replace .................. 119
Hydraulic System Oil Sample - Obtain ............... 121
Parking Brake - Drain ......................................... 123
Tandem Breather - Clean/Replace ..................... 128
Tandem Drive Oil Sample - Obtain ..................... 129
Transmission and Differential Oil Filter and Screens -
Replace/Clean .................................................. 131
Transmission and Differential Oil Sample -
Obtain ............................................................... 133

Every 1000 Service Hours or 6 Months

Blade Cushion Accumulator - Check .................... 83
Rollover Protective Structure (ROPS) - Inspect .. 126
Steering Accumulator - Check ............................ 128
Transmission and Differential Oil - Change ........ 130

Every 2000 Service Hours or 2 Years

Air Dryer Desiccant - Replace .............................. 80
Battery or Battery Cable - Inspect/Replace .......... 82
Circle Drive Oil - Change ...................................... 90
Condenser (Refrigerant) - Clean .......................... 92
Cooling System Pressure Cap - Clean/Replace ... 97
Crankshaft Vibration Damper - Inspect ................. 99
Engine Valve Lash - Check .................................. 110
Engine Valve Rotators - Inspect .......................... 110
Evaporator Coil and Heater Coil - Clean ............. 110
Final Drive Preload - Check ................................. 111
Refrigerant Dryer - Replace ................................ 124
Tandem Drive Oil - Change ................................ 128
Wheel Bearing Oil (Front) - Change ................... 134

Every Year
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 94

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 ............................................................... 98

Every 4000 Service Hours

Hydraulic System Oil - Change ............................ 118
80 SEBU7474-03
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
9:00 position in order to drain the other air tank. Illustration 78
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.
SEBU7474-03 81
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.
82 SEBU7474-03
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.
SEBU7474-03 83
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
84 SEBU7474-03
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.
SEBU7474-03 85
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.
86 SEBU7474-03
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.
SEBU7474-03 87
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.
88 SEBU7474-03
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).
SEBU7474-03 89
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.
90 SEBU7474-03
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
Illustration 98 NOTICE
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).
SEBU7474-03 91
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).
92 SEBU7474-03
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.
SEBU7474-03 93
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.
94 SEBU7474-03
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.
SEBU7474-03 95
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.
96 SEBU7474-03
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-NL;
1352-544; 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.

SEBU7474-03 97
Maintenance Section
Cooling System Coolant Level - Check

i01889958

Cooling System Coolant Level

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

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.
98 SEBU7474-03
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.
SEBU7474-03 99
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.
100 SEBU7474-03
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
SEBU7474-03 101
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.
102 SEBU7474-03
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.
SEBU7474-03 103
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.
104 SEBU7474-03
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.
SEBU7474-03 105
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).

106 SEBU7474-03
Maintenance Section
Engine Crankcase Breather - Replace

i01632265 5. Clean the oil filler cap and install the oil filler cap.
Engine Crankcase Breather - 6. Close the access door.
Replace
i01893113
SMCS Code: 1317-510
Engine Oil Sample - Obtain
Only replace the engine crankcase breather when
you rebuild the engine. SMCS Code: 1348-008; 1348-554-SM; 7542-008;
7542-554-OC, SM
i01892889
Refer to the Operation and Maintenance Manual,
Engine Oil Level - Check “Access Doors and Covers” for the location of the
service points.
SMCS Code: 1000-535-FLV; 1302-535-FLV;
1326-535-OC; 1326-535-FLV; 1348-535-FLV

Hot oil and hot components can cause personal

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.

g00985412
Refer to the Operation and Maintenance Manual, Illustration 129
“Access Doors and Covers” for the location of the
service points. The sampling valve for the engine oil is located on
the left side of the engine compartment.
1. Open the access door.
Refer to Special Publication, SEBU6250, “Caterpillar
2. Clean the area around the dipstick and clean the Machine Fluids Recommendations”, “S·O·S Oil
area around the oil filler cap before you remove Analysis” for information that pertains to obtaining a
the dipstick and the oil filler cap. 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.

g00985409
Illustration 128

3. Before starting the engine, check the “ENGINE

STOPPED” side of dipstick (1) while the engine is
stopped. Maintain the oil level between the “ADD”
mark and the “FULL” mark.

4. Remove oil filler cap (2). If necessary, add oil.

SEBU7474-03 107
Maintenance Section
Engine Oil and Filter - Change

i01893190 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 9. 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 9
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 9. 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 9 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.
108 SEBU7474-03
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
products.
• Shorten the oil change interval to 250 hours.
Dispose of all fluids according to local regulations and
• Proceed to Program B. mandates.
• Change to a preferred oil type in Table 9.
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”

Reference: Special Publication, PEDP7036, “S·O·S

Fluid Analysis”

Reference: Special Publication, PEDP7076,

“Understanding S·O·S Services Test”

g00804939
Illustration 131
SEBU7474-03 109
Maintenance Section
Engine Overheating

1. Open crankcase drain valve (1). Allow the oil to i01900293

drain into a suitable container.
Engine Overheating
Note: Discard any drained fluids and discard any
filter elements according to local regulations. SMCS Code: 1000; 1350; 1353

2. Close crankcase drain valve (1). If your machine experiences an engine overheating
problem, do the following maintenance procedures
3. Open the left side access door in order to service in the order that is listed:
the oil filter.
1. Operation and Maintenance Manual, “Cooling
System Coolant Level − Check”

2. Operation and Maintenance Manual, “Radiator -

Clean”

3. Operation and Maintenance Manual, “Belt -

Inspect”

4. Operation and Maintenance Manual, “Cooling

System Pressure Cap - Clean/Replace”

5. Operation and Maintenance Manual, “Radiator

Core - Clean”
g00985474
Illustration 132 6. Operation and Maintenance Manual, “Cooling
System Water Temperature Regulator - Replace”
4. Clean the area around engine oil filter (2) before
you remove the engine oil filter. Remove the If the engine overheating problem is not corrected,
engine oil filter with a strap type wrench. See consult your Caterpillar dealer.
Operation and Maintenance Manual, “Oil Filter -
Inspect”.
i01900299

5. Clean the base of the engine oil filter housing.

Make sure that all of the old filter gasket is
Engine Power Loss
removed. SMCS Code: 1000; 1051; 1250
6. Apply a light coat of engine oil to the gasket of the If your machine experiences an engine power loss,
new engine oil filter. perform the following maintenance procedures in the
order that is listed:
7. Install the new engine oil filter by hand. Additionally
tighten the engine oil filter by 3/4 of a turn, after 1. Operation and Maintenance Manual, “Engine Air
the gasket contacts the filter base. Filter Service Indicator - Inspect”
8. Clean the area around dipstick (4) before you 2. Operation and Maintenance Manual, “Engine Air
remove the dipstick. Clean the area around oil Precleaner - Clean”
filler cap (3) before you remove the oil filler cap.
Remove oil filler cap (3). Fill the crankcase with 3. Operation and Maintenance Manual, “Engine Air
new oil. See Operation and Maintenance Manual, Filter Primary Element - Clean/Replace”
“Capacities (Refill)”. Clean the filler cap and install
the filler cap. 4. Operation and Maintenance Manual, “Engine Air
Filter Secondary Element - Replace”
9. Start the engine and allow the oil to warm. Check
the engine for leaks. 5. Operation and Maintenance Manual, “Fuel Tank
Water and Sediment - Drain”
10. Stop the engine. Check the “ENGINE STOPPED”
side of dipstick (4) while the engine is stopped. 6. Operation and Maintenance Manual, “Fuel Tank
Maintain the oil level between the “ADD” mark and Cap and Strainer - Clean”
the “FULL” mark. If necessary, add oil .
7. Operation and Maintenance Manual, “Fuel System
11. Close the left side access door on the machine. Water Separator Element - Replace”
110 SEBU7474-03
Maintenance Section
Engine Valve Lash - Check

8. Operation and Maintenance Manual, “Fuel System i00128925

Secondary Filter - Replace”
Engine Valve Rotators - Inspect
If the power loss is not corrected, consult your
Caterpillar dealer. SMCS Code: 1109-040

i01498587

Engine Valve Lash - Check When inspecting the valve rotators, protective
glasses or face shield and protective clothing
SMCS Code: 1105-535 must be worn, to prevent being burned by hot oil
spray.

Inspect the engine valve rotators after the valve

Ensure that the engine can not be started while clearances have been set.
this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor 1. Start the engine and run the engine at low idle.
to turn the flywheel.
2. Watch the top surface of each valve rotator. When
Hot engine components can cause burns. Allow the intake valve or the exhaust valve closes, the
additional time for the engine to cool before mea- engine valve rotator should turn slightly.
suring/adjusting valve lash clearance.
If an intake valve or an exhaust valve fails to rotate,
consult your Caterpillar Dealer.
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your i01827363

Caterpillar dealer for the complete valve lash adjust-

ment procedure.
Evaporator Coil and Heater
Coil - Clean
Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This re- SMCS Code: 7309-070; 7343-070
duced efficiency could result in excessive fuel usage
and/or shortened engine component life. The evaporator coil and the heater coil are located
under the seat in the cab.
NOTICE 1. Remove the seat.
Do not use the yoke that comes out of the front of the
engine in order to turn over the engine. Damage to the 2. Remove both of the covers.
crankshaft vibration damper can occur.

The adjustment is necessary due to the initial wear of

the valve train components and to the seating of the
valve train components.

This maintenance is recommended by Caterpillar

as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.

Ensure that the engine is stopped before you

measure the valve lash. To obtain an accurate
measurement, allow the valves to cool before you
perform this maintenance.

Remove the cover in order to access the rear of

the engine. Check the valve lash. For the correct
adjustment procedure, refer to Systems Operation,
Testing and Adjusting, “Engine Valve Lash -
Inspect/Adjust”.
g00931904
Illustration 133
SEBU7474-03 111
Maintenance Section
Final Drive Preload - Check

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.

i01893215

Final Drive Preload - Check

SMCS Code: 4050-535-ZP
g00949715
Illustration 134
Table 10
Required Tools 6. Remove outer cover (1).
Part Number Description Quantity
Wrench for 120H
6V-4074 1
Wrench for 135H
Torque Wrench Gp
9U-5015 1
(3/4 Inch Drive)

Table 11
Bearing Preload for the Final Drive
Sales Model Final Torque
120H
102 N·m (75 lb ft)
135H
g00949716
Illustration 135

1. Park the machine on a level surface. 7. Remove lock (2).

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.

g00985487
Illustration 136

8. Install the wrench for your machine to the

appropriate torque wrench.

9. Check the torque. Refer to Table 11.

10. Refer to the adjustment procedure inthe Power

Train Systems Operation, Testing and Adjusting,
“Final Drive Bearings - Adjust” if the torque is
incorrect.
112 SEBU7474-03
Maintenance Section
Fuel System - Fill

i02573704 4. Install filler cap (1).

Fuel System - Fill Note: Prime the fuel system. See Operation and
Maintenance Manual, “Fuel System - Prime” for more
SMCS Code: 1250-544 information.

Machines that are Equipped with a

Personal injury or death may result from failure to Fast Fill Fuel Arrangement
adhere to the following procedures.
NOTICE
Fuel leaked or spilled onto hot surfaces or electri- Use only a Caterpillar approved fast fill system to fuel
cal components can cause a fire. machines. Over pressurization may cause tank defor-
mation and fuel spillage.
Clean up all leaked or spilled fuel. Do not smoke
while working on the fuel system. Contact your Cat dealer for fast fill system availability.
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.
g01288825
Illustration 138
Reference: See Operation and Maintenance Manual,
Typical example
“Capacities (Refill)” for the capacity of the fuel tank
for your machine.
1. Park the machine on a level surface.
Refer to Operation and Maintenance Manual,
“Access Doors and Covers” for the location of the 2. Remove dust cover (3), if equipped.
service points.
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.

g00933829
Illustration 137

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

2. Remove filler cap (1).

3. Fill fuel tank (2) with fuel.

SEBU7474-03 113
Maintenance Section
Fuel System - Prime

i01893653 i01892756

Fuel System - Prime Fuel System Secondary Filter -

SMCS Code: 1250-548; 1258-548
Replace
SMCS Code: 1261-510-SE
NOTICE
Care must be taken to ensure that fluids are contained S/N: CBC1-Up
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to S/N: CAF1-Up
collect the fluid with suitable containers before open- S/N: AMX1-Up
ing any compartment or disassembling any compo-
nent containing fluids. S/N: ALZ1-Up

Refer to Special Publication, NENG2500, “Caterpillar

NOTICE
Tools and Shop Products Guide” for tools and supplies
Do not fill fuel filters with fuel before installing them.
suitable to collect and contain fluids on Caterpillar
Contaminated fuel will cause accelerated wear to fuel
products.
system parts.
Dispose of all fluids according to local regulations and
mandates. NOTICE
Care must be taken to ensure that fluids are contained
The fuel system is primed in order to fill the fuel filter. during performance of inspection, maintenance, test-
The fuel system is also primed in order to purge ing, adjusting and repair of the product. Be prepared to
trapped air. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
The fuel priming pump is located on the top of the nent containing fluids.
water separator on the right side of the machine. The
fuel priming is automatically controlled by the engine Refer to Special Publication, NENG2500, “Caterpillar
ECM. Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
1. Turn the start switch key to the ON position in products.
order to fill the filter element with fuel.
Dispose of all fluids according to local regulations and
Note: The fuel system should be primed within two mandates.
minutes. If the time was more than two minutes,
change the filter element and repeat the priming Refer to the Operation and Maintenance Manual,
procedures. “Access Doors and Covers” for the location of the
service points.
2. Start the engine. If the engine starts but the engine
runs rough, allow the engine to run at low idle. 1. Open the access door.
Continue to run the engine at low idle until the
engine runs smoothly.

3. Stop the engine.

g00985199
Illustration 139

2. Remove fuel filter (1).

114 SEBU7474-03
Maintenance Section
Fuel System Water Separator - Drain

3. Drain the fuel from fuel filter (1) into a suitable

container.

Note: Discard any drained fluids according to local

regulations.

4. Clean the mounting base for the fuel filter. Make

sure that you remove all of the old seal.

5. Coat the seal of the new fuel filter with clean

diesel fuel.

6. Install the new fuel filter by hand. Tighten the new

fuel filter until the seal contacts the mounting base.
Then tighten the new fuel filter by an additional g00985249
3/4 of a turn. Illustration 140

Use the rotation index marks on the new fuel filter 2. Open drain (1) and allow the water and sediment
as a guide for tightening the filter. These rotation to drain into a suitable container.
index marks are spaced at intervals of 1/4 turn.
3. Close drain (1).
7. Close the access door.
4. Close the access door.

i01892803
i01892728
Fuel System Water Separator Fuel System Water Separator
- Drain Element - Replace
SMCS Code: 1263-543
SMCS Code: 1263-510-FQ
S/N: CBC1-Up
S/N: CAF1-Up
S/N: AMX1-Up Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire.
S/N: ALZ1-Up
Turn the disconnect switch OFF when draining
NOTICE and/or removing any fuel system components.
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 NOTICE
collect the fluid with suitable containers before open- Do not fill fuel filters with fuel before installing them.
ing any compartment or disassembling any compo- Contaminated fuel will cause accelerated wear to fuel
nent containing fluids. system parts.

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.

1. Open the access door.

SEBU7474-03 115
Maintenance Section
Fuel Tank Cap and Strainer - Clean

9. Install the filter element onto the filter housing.

NOTICE
Care must be taken to ensure that fluids are contained 10. Close the access door.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to i01863218
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- Fuel Tank Cap and Strainer -
nent containing fluids.
Clean
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies SMCS Code: 1273-070-STR; 1273-070-Z2
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.

1. Open the access door.

g00949816
Illustration 142

1. Remove fuel tank cap (1) and disassemble the

fuel tank cap.

2. Inspect the seal on the fuel tank cap for damage.

If the seal is damaged, replace the seal. Lubricate
g00985190
the seal on the fuel tank cap.
Illustration 141
3. Replace the elements on the fuel tank cap.
2. In order to drain filter (2), open drain valve (1) on
water separator bowl (3). The water separator 4. Remove the strainer from the filler opening.
bowl is under filter (2). Catch the fuel in a suitable
container. 5. Wash the strainer in clean nonflammable solvent.
3. Remove filter (2) and water separator bowl (3). 6. Install the strainer.
4. Remove water separator bowl (3) from the filter 7. Install fuel tank cap (1).
element (2).

5. Wash water separator bowl (3) in a clean

nonflammable solvent. Use pressure air to dry
water separator bowl (3).

6. Install the clean water separator bowl onto a new

filter element.

7. Clean the filter housing base.

8. Coat the seal of the new filter element with clean

diesel fuel.
116 SEBU7474-03
Maintenance Section
Fuel Tank Water and Sediment - Drain

i01830349

Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543-M&S

g00935115
Illustration 144
(1) Fuse panel on the steering console (unswitched power)
(2) Fuse panel on the steering console (switched power)

g00934388
Illustration 143

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. g00935093

Illustration 145

Note: If you need to flush the fuel sump, use drain (3) Overhead fuse panel
valve (2) that is located under the rear frame on the
right side of the machine. 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
i01863227 side of the operator.
Fuses - Replace
SMCS Code: 1417-510

Fuses – Fuses protect the electrical system from

damage that is caused by overloaded circuits.
Replace the fuse if the element is separated. Check
the circuit if the element is separated in a new fuse.
Repair the circuit.

NOTICE
Replace the fuses with the same type and size only.

If it is necessary to replace fuses frequently, an electri-

g00778429
cal problem may exist. Consult your Caterpillar dealer. Illustration 146
Fuse panel on the steering console (unswitched power)

Tail Lights and Panel Lights (4) (If

Equipped) – 10 amp
SEBU7474-03 117
Maintenance Section
Fuses - Replace

Secondary Steering (Test) (5) – 10 amp

Key Switch (6) – 10 amp

Auxiliary Power Port (7) (If Equipped) –

10 amp

Horn (8) – 10 amp

g00778430
Illustration 147
Fuse panel on the steering console (switched power)

Turn Signals and Hazard Lamps (9) (If Digital Electrical Monitoring System
Equipped) – 10 amp (16) – 10 amp

Lighter (10) – 10 amp Blade Floodlights (17) (If Equipped) – 10

amp

Communication Radio (11) (If Rear Floodlights (18) (If Equipped) – 10

Equipped) – 15 amp amp

Stop Lamps (12) – 10 amp All Wheel Drive (19) (If Equipped) – 10
amp

Radio (13) (If Equipped) – 10 amp Air Dryer (20) – 10 amp

Dome Lamp (14) – 10 amp Differential Lock (21) – 10 amp

Product Link (15) – 10 amp Heating and Air Conditioning System

(22) – 15 amp

Blade Cushion (If Equipped) and

Centershift Lock Pin (23) – 10 amp

Transmission Control (24) – 15 amp

Front Floodlights (25) (If Equipped) – 15

amp
118 SEBU7474-03
Maintenance Section
Hydraulic System Oil - Change

Parking Brake (26) – 10 amp Rear Window Defroster (36) – 10 amp

Fuel System (27) – 10 amp Exterior Heated Mirrors (37) (If

Equipped) – 10 amp

Secondary Steering (28) (If Equipped) –

i01902074
10 amp
Hydraulic System Oil - Change
Beacon (29) (If Equipped) – 10 amp 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.
g00778432
Illustration 148
Overhead fuse panel Note: If the hydraulic oil is not being monitored
by the Caterpillar S·O·S Oil Analysis program or
Front Windshield Wiper/Washer (30) – an equivalent oil sampling program, change the
15 amp hydraulic oil at every 2000 service hour interval.

Auxiliary Backup Lights (31) (If

Equipped) – 10 amp Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact skin.
Rear Window Wiper and Washer (32) –
10 amp
Operate the machine until the oil is warm.

Park the machine on a level surface with the front

Snow Wing Light (33) (If Equipped) – 10 wheel straight ahead. Lower all attachments to the
amp 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
Front Windshield Defroster (34) – 10 must move freely in the frame. Move the front wheels
amp to vertical and install the wheel lean bolt. Engage the
parking brake. Stop the engine.

Moldboard Lights (35) (If Equipped) – 10 The hydraulic system oil tank is positioned behind
amp the operator station at the center of the machine.
SEBU7474-03 119
Maintenance Section
Hydraulic System Oil Filter - Replace

9. Install the hydraulic oil filler cap.

10. Start the engine. Run the engine for a few

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.
g00932315
Illustration 149
NOTICE
1. Slowly remove hydraulic oil filler cap (1). Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
2. Drain plug (2) is positioned in the bottom of the ing, adjusting and repair of the product. Be prepared to
hydraulic oil tank. Remove the drain plug. Drain collect the fluid with suitable containers before open-
the oil into a suitable container. ing any compartment or disassembling any compo-
nent containing fluids.
3. Replace the filter for the hydraulic system oil. See
Operation and Maintenance Manual, “Hydraulic Refer to Special Publication, NENG2500, “Caterpillar
System Oil Filter - Replace” in the Maintenance Tools and Shop Products Guide” for tools and supplies
Interval Schedule. suitable to collect and contain fluids on Caterpillar
products.
4. Remove the filler screen from the filler tube in the
hydraulic oil tank. Wash the filler screen in clean Dispose of all fluids according to local regulations and
nonflammable solvent. Allow the filler screen to mandates.
dry.
Park the machine on a level surface with front wheels
5. Clean the drain plug and install the drain plug. straight ahead. Lower all attachments to the ground.
Apply a slight downward pressure to the attachments.
6. Install the filler screen. Center the articulation of the machine and install the
frame lock pin. The frame lock pin must move freely
7. Fill the hydraulic system oil tank. See Operation in the frame. Move the front wheels to vertical and
and Maintenance Manual, “Capacities (Refill)”. 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.
120 SEBU7474-03
Maintenance Section
Hydraulic System Oil Level - Check

Clean the area around the filler cap before you i01827874
remove the filler cap. Clean the area around the filter
cover before you remove the filter cover. 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.

g00932333
Illustration 150

1. Slowly remove hydraulic oil filler cap (1) in order

to relieve the tank pressure.

2. Remove filter cover (2) from the hydraulic system

oil tank.

3. Inspect the seal for the cover. If necessary, replace

the seal.

4. Remove the filter element and discard the filter

element.

5. Install a new filter element.

6. Install cover (2).

7. Maintain the hydraulic oil level above the “MIN”

mark on sight gauge (3).

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

is damaged, replace the filler cap gasket. Install
the oil filler cap.
SEBU7474-03 121
Maintenance Section
Hydraulic System Oil Sample - Obtain

i01886347

Hydraulic System Oil Sample

- Obtain
SMCS Code: 4129-008; 5050-008; 5056-008;
5095-008; 5095-SM

g00979019
Illustration 152

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
Sample” for more information about obtaining a
sample of the hydraulic oil.
g00932336
Illustration 151
i01886332
1. Maintain the oil level above the “MIN” mark on
sight gauge (1). Kingpin Bearings - Lubricate
2. If necessary, add oil. Slowly loosen the filler cap in SMCS Code: 4314-086
order to relieve the tank pressure. Remove filler
cap (2). Add oil through the filler tube. Wipe all the fittings before you apply lubricant to the
fittings.
3. Clean the filler cap and install the filler cap.

g00979000
Illustration 153
122 SEBU7474-03
Maintenance Section
Moldboard Wear Strip - Inspect/Adjust/Replace

The kingpins are located to the inside of the front 7. Remove the top retaining plate from the center
wheels. Each front wheel has a kingpin. Each kingpin wear strip bracket. Visually inspect the wear strips.
has two fittings. In order to lubricate the kingpin If the wear strips are worn close to the moldboard,
bearings, use 183-3424 Grease Cartridge to apply replace the wear strips.
lubricant to the fittings.
8. Install shims between the moldboard rail and the
wear strips at the location of minimum clearance.
i01830090
Add shims in order to provide a clearance of
Moldboard Wear Strip - 0.13 mm (0.005 inch) to 0.89 mm (0.035 inch).

Inspect/Adjust/Replace 9. Install the top retaining plate for the center wear
strip bracket.
SMCS Code: 6174-025; 6174-040; 6174-510
i02106227
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.
Oil Filter - Inspect
SMCS Code: 1308-507; 3004-507; 3067-507;
5068-507

Inspect a Used Filter for Debris

g00934204
Illustration 154

2. Remove the top retaining plates and the bottom

retaining plates. Visually inspect the wear strips. If
the wear strips are worn close to the moldboard,
g00100013
replace the wear strips. Illustration 155
The element is shown with debris.
3. Install shims between the moldboard rail and the
wear strips at the location of minimum clearance. Use a filter cutter to cut the filter element open.
Add shims in order to provide a clearance of Spread apart the pleats and inspect the element for
0.13 mm (0.005 inch) to 0.89 mm (0.035 inch). metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
Note: The shims that are required should be divided failure.
evenly between the upper wear strips and the lower
wear strips. If metals are found in the filter element, a magnet can
be used to differentiate between ferrous metals and
4. Install the top retaining plate and install the bottom nonferrous metals.
retaining plate.
Ferrous metals can indicate wear on steel parts and
5. Start the engine. Raise the blade, so that the on cast iron parts.
blade will clear the ground. Sideshift the blade
through the entire limit of travel. Measure the Nonferrous metals can indicate wear on the
clearance between the wear strips and the blade. aluminum parts of the engine such as main bearings,
This will allow you to determine the location of the rod bearings, or turbocharger bearings.
minimum clearance.
Small amounts of debris may be found in the filter
6. Stop the engine. 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.
SEBU7474-03 123
Maintenance Section
Parking Brake - Drain

Using an oil filter element that is not recommended

by Caterpillar can result in severe engine damage
to engine bearings, to the crankshaft, and to other
parts. This can result in larger particles in unfiltered
oil. The particles could enter the lubricating system
and the particles could cause damage.

i01863714

Parking Brake - Drain

SMCS Code: 4267-543-M&S

g00950101
Illustration 156
Sudden movement of the machine or release of (1) Parking brake
air under pressure can cause injury to persons on (2) Outer plug
or near the machine. To prevent possible injury,
perform the procedure that follows before testing 1. Remove outer plug (2) and an inner plug (not
and adjusting the air system and brakes. shown) behind outer plug (2).

2. Start the engine. Make sure that the air system

NOTICE pressure reaches 965 ± 34 kPa (140 ± 5 psi).
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.
g00950104
Illustration 157
1. Move the machine to a smooth horizontal location.
Move away from operating machines and move (3) Transmission control (lever)
away from personnel. Lower all implements to the
ground. 3. Make sure that the service brake control (pedal)
is down. Move lever (3) from PARKING BRAKE
2. Install the wheel lean locking bolt in the front axle. ENGAGED position to the NEUTRAL position
Install the frame lock pin. Engage the parking and back to the PARKING BRAKE ENGAGED
brake and stop the engine. position.

3. Permit only one operator on the machine. Keep all 4. Continue to move lever (3) from PARKING BRAKE
other personnel away from the machine. Also, all ENGAGED position to the NEUTRAL position
personnel should be visible to the operator. and back to the PARKING BRAKE ENGAGED
position. This will drain the moisture from parking
4. Place chocks in front of the wheels and behind brake (1).
the wheels.
5. Stop the engine and allow the air to escape from
the system. Replace the inner plug and outer plug
(2).
124 SEBU7474-03
Maintenance Section
Radiator - Clean

i01863242 i01827882

Radiator - Clean Refrigerant Dryer - Replace

SMCS Code: 1353-070; 1805-070; 1810-070 SMCS Code: 7322-510

Personal injury can result from contact with refrig-

erant.

Contact with refrigerant can cause frost bite. Keep

face and hands away to help prevent injury.

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.

Illustration 158 g00949836 Slowly loosen the fitting. If the system is still un-
der pressure, release it slowly in a well ventilated
1. Remove the access cover on the left rear of the area.
machine. Remove the access cover on the right
rear of the machine. Personal injury or death can result from inhaling
refrigerant through a lit cigarette.
2. Remove any dirt from the area around the radiator.
Remove any debris from the area around the Inhaling air conditioner refrigerant gas through a
radiator. lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air con-
3. Install the access covers. ditioner refrigerant gas, can cause bodily harm or
death.

i01671005 Do not smoke when servicing air conditioners or

wherever refrigerant gas may be present.
Radiator Core - Clean
Use a certified recovery and recycling cart to prop-
SMCS Code: 1353-070; 1353-070-KO erly remove the refrigerant from the air condition-
ing system.
You can use compressed air, high pressure water,
or steam to remove dust and other debris from the
radiator core. However, the use of compressed air
is preferred.

See Special Publication, SEBD0518, “Know Your

Cooling System” for the complete procedure for
cleaning the radiator core.

g00812585
Illustration 159

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.
SEBU7474-03 125
Maintenance Section
Ripper Cylinder Bearings - Lubricate

Note: When you operate the machine in a climate

with high humidity, replace the in-line refrigerant dryer
after every 1000 service hours or 6 months.
Retainer pin, when struck with force, can fly out
and cause injury to nearby people.
i01863759
Make sure the area is clear of people when driving
Ripper Cylinder Bearings - retainer pins.
Lubricate To avoid injury to your eyes, wear protective
glasses when striking a retainer pin.
SMCS Code: 5352-086; 6325-086

Wipe all the fittings before you apply lubricant to the Inspect the ripper tips. Replace the ripper tips if the
fittings. tips are damaged or the tips are worn excessively.

1. Block up the ripper to a height that is adequate for

the removal of the tips.

g00853256
Illustration 160

The trunnion has one fitting (1) on each side. Use

183-3424 Grease Cartridge to apply lubricant to Illustration 161 g00110460

each fitting (1).

2. Drive out the retainer pin from the retainer side
One fitting (2) is mounted on the rod end of the ripper of the ripper tip. Remove the ripper tip and the
cylinder. Use 183-3424 Grease Cartridge to apply retainer.
lubricant to fitting (2).
3. Clean the adapter, the retainer pin, and the
retainer. Install the retainer in the groove.
i01563909

Ripper Tip - Inspect/Replace 4. Install the new ripper tip over the retainer.

SMCS Code: 6808-040; 6808-510 5. Drive the retainer pin through the retainer, through
the adapter, and through the ripper tip from the
opposite side of the retainer.

6. Repeat Step 2 through Step 5 in order to replace

Personal injury or death can result from the ripper additional ripper tips.
falling.
7. Raise the ripper. Remove the block. Lower the
Block the ripper before changing teeth. ripper to the ground.
126 SEBU7474-03
Maintenance Section
Rollover Protective Structure (ROPS) - Inspect

i01831248 i01863262

Rollover Protective Structure Scarifier Lift Link Socket -

(ROPS) - Inspect Lubricate
SMCS Code: 7323-040; 7325-040 SMCS Code: 6162-086-LNK

NOTICE Wipe all the fittings before you apply lubricant to the
Do not attempt to straighten the ROPS structure. Do fittings.
not repair the ROPS by welding reinforcement plates
to the structure.

If there are any cracks in the welds, in the castings, or

in any metal section of the ROPS, consult your Cater-
pillar dealer for repairs.

g00949846
Illustration 163

The machine has two fittings on each side.

In order to lubricate the scarifier lift link socket, use

183-3424 Grease Cartridge (5% Molybdenum
g00935191
Disulfide) to apply lubricant through the fittings.
Illustration 162

1. There are two retaining pins for the ROPS. One i01863797
retaining pin is located on each side of the cab.
Remove the access covers (1) from the retaining Scarifier Teeth -
pin locations. Inspect/Replace
2. Inspect the retaining pins. Inspect the keeper bolt. SMCS Code: 6807-040; 6807-510
Replace any damaged keeper bolts or any missing
keeper bolts with only original equipment parts.

3. Install the access covers.

Personal injury or death can result from the scar-
4. Inspect the ROPS for any loose bolts or any ifier falling.
damaged bolts. Replace any damaged bolts or
any missing bolts with only the original equipment Block the scarifier before changing the teeth.
parts. Tighten the four rear bolts (2) to a torque of
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
(180 ± 30 lb ft).
Flying objects can cause injury or death.
Note: Apply oil to all ROPS bolt threads before you
install the bolts for the ROPS. Failure to apply oil can Make sure the area is clear of people when remov-
result in improper bolt torque. ing/installing scarifier teeth.

5. When you operate the machine on a rough To avoid injury to your eyes, wear protective
surface, the ROPS may rattle or the ROPS may glasses when removing/installing scarifier teeth.
make a noise. If the ROPS rattles or if the ROPS
makes a noise, replace the ROPS mounting If the scarifier teeth are damaged or worn excessively,
supports . then change the scarifier teeth.
SEBU7474-03 127
Maintenance Section
Seat Belt - Inspect

Check the seat belt mounting hardware (1) for wear

or for damage. Replace any mounting hardware that
is worn or damaged. Make sure that the mounting
bolts are tight.

Check buckle (2) for wear or for damage. If the buckle

is worn or damaged, replace the seat belt.

Inspect the seat belt (3) for webbing that is worn or

frayed. Replace the seat belt if the seat belt is worn
or frayed.

Consult your Caterpillar dealer for the replacement of

the seat belt and the mounting hardware.
g00950158
Illustration 164 Note: Within three years of the date of installation or
within five years of the date of manufacture, replace
1. Block up the scarifier. Do not block up the scarifier the seat belt. Replace the seat belt at the date which
too high. Block up the scarifier to a height that occurs first. A date label for determining the age of
allows you to remove the teeth. the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.
2. Remove the scarifier tooth from the shank.
If your machine is equipped with a seat belt
3. Clean the shank. extension, also perform this inspection procedure for
the seat belt extension.
4. Install the new scarifier tooth over the shank.

5. Drive the scarifier tooth onto the shank. i02429594

6. Repeat Step 2 through Step 5 in order to replace Seat Belt - Replace

additional scarifier teeth.
SMCS Code: 7327-510
7. Raise the scarifier and remove blocking.
Within three years of the date of installation or within
five years of the date of manufacture, replace the
i02429589 seat belt . Replace the seat belt at the date which
occurs first. A date label for determining the age of
Seat Belt - Inspect the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.
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
damaged or worn before you operate the machine.

g01152685
Illustration 166
(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

g00932801 the seat belt and the mounting hardware.
Illustration 165
Typical example
128 SEBU7474-03
Maintenance Section
Steering Accumulator - Check

If your machine is equipped with a seat belt i02402581

extension, also perform this replacement procedure
for the seat belt extension. Tandem Breather -
Clean/Replace
i01886419
SMCS Code: 4062-070-BRE; 4062-510-BRE
Steering Accumulator - Check
(If Equipped)
SMCS Code: 4331-535

g00933727
Illustration 168
Typical example

Note: The tandem breather for your machine may be

Illustration 167 g00938287 located closer to the front of the tandem housing.
The steering accumulator is located under the operator’s platform
on the left side of the machine. 1. Remove breathers (1) from both tandems.

Steer the machine to the left and steer the machine 2. Wash breathers (1) in clean, nonflammable
to the right. If the movement of the steering system solvent.
is abnormal, check the nitrogen precharge. Operate
the hydraulic equipment. If the movement of the 3. Use pressure air to dry breathers (1).
steering is abnormal, check the nitrogen precharge.
If necessary, add nitrogen. Consult your Caterpillar 4. Install breathers (1) in both tandems.
dealer for the correct checking procedure, the correct
filling procedure and the recommended pressure. Note: Replace breathers (1) if the breathers are
damaged.

i01829602

Tandem Drive Oil - Change

SMCS Code: 4071-510

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.
SEBU7474-03 129
Maintenance Section
Tandem Drive Oil Level - Check

Clean the surface area around the oil check plug

before you check the oil level.

g00933714
Illustration 170

Illustration 169 g00933690 1. Remove the oil check plug.

1. Remove drain plug (1). Remove oil check plug (2). 2. Maintain the oil level at the bottom of the opening
Allow the oil to drain into a suitable container. for the oil check plug. If necessary, add oil. Open
the cover on the top of the tandem drive housing
2. When you change the tandem drive oil, use diesel and add oil. Close the cover on the top of the
fuel in order to clean the housing of the sludge tandem drive housing.
and flush the housing of the sludge.
3. Install the oil check plug.
3. Clean the drain plug (1) and install the drain plug
(1). i01958878

4. Open the cover on the top of the tandem drive Tandem Drive Oil Sample -
housing. Fill the tandem drive housing with new
oil. See Operation and Maintenance Manual, Obtain
“Capacities (Refill)”.
SMCS Code: 4071-008
5. Close the cover on the top of the tandem drive
housing.

6. Clean the oil check plug (2) and install the oil
check plug (2).

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

minutes. Check the tandem drive housing for
leaks.

8. Stop the engine. Remove the oil check plug (2).

Check the oil level. Maintain the oil level to the
bottom of the opening for the oil check plug (2). If
necessary, add oil. Install the oil check plug (2).
g00933718
Illustration 171
9. Repeat Step 1 through Step 8 for the other side.
The oil sample for the tandem drive should be taken
i01829619 from the housing by removing one of the plates that
are located on the top of the tandem housing.
Tandem Drive Oil Level - Check
Refer to Special Publication, SEBU6250, “Caterpillar
SMCS Code: 4071-535 Machine Fluids Recommendations”, “S·O·S Oil
Analysis” for information that pertains to obtaining
Clean the surface area around the oil check plug a sample of the tandem drive oil. Refer to Special
before you check the oil level. Publication, PEHP6001, “How To Take A Good Oil
Sample” for more information about obtaining a
sample of the tandem drive oil.
130 SEBU7474-03
Maintenance Section
Tire Inflation - Check

i00149440

NOTICE
Tire Inflation - Check Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
SMCS Code: 4203-535-PX; 4203-535-AI 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.

Refer to the Operation and Maintenance Manual,

“Access Doors and Covers” for the location of the
g00103147
Illustration 172 service points.

Measure the air pressure on each tire. Consult your Clean the area around the drain plug for the
tire dealer for the correct load rating and for the differential and the transmission before removing the
correct operating pressures. drain plug. Clean the area around the dipstick/fill cap
before removing the dipstick/fill cap.
If necessary, inflate the tires. Refer to the following
additional information about tire inflation: Operate the engine until the transmission and
differential oil is warm. Park the machine on a level
• Operation and Maintenance Manual, “Tire Inflation surface and engage the parking brake. Lower the
with Nitrogen” blade and apply slight down pressure to the blade.
Stop the engine.
• Operation and Maintenance Manual, “Tire Shipping
Pressure” Note: Drain the transmission and differential case
while the oil is warm. This allows waste particles that
• Operation and Maintenance Manual, “Tire Inflation are suspended in the oil to drain. As the oil cools, the
Pressure Adjustment” waste particles will settle to the bottom of the case.
The particles will not be removed by draining the
oil and the particles will recirculate in the lubrication
i01895796
system with the new oil.
Transmission and Differential
Oil - Change
SMCS Code: 3080-510; 3258-510-OC

Hot oil and hot components can cause personal

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

g00986407
Illustration 173

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

transmission case. Drain the oil into a suitable
container.
SEBU7474-03 131
Maintenance Section
Transmission and Differential Oil Filter and Screens - Replace/Clean

2. Change the filter element and clean the screens. i01893231

See the Operation and Maintenance Manual,
“Transmission and Differential Oil Filter and Transmission and Differential
Screens - Replace/Clean”. Oil Filter and Screens -
3. Clean the drain plug and install the drain plug for Replace/Clean
the differential and transmission case.
SMCS Code: 3030-070-Z3; 3030-510-Z3;
3067-070; 3067-510; 3258-070-FI; 3258-070-Z3;
3258-510-Z3; 3258-510-FI

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-
g00986408 ing, adjusting and repair of the product. Be prepared to
Illustration 174 collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
4. Open the access door. nent containing fluids.
5. Fill the transmission and differential case with Refer to Special Publication, NENG2500, “Caterpillar
oil through filler tube (2). See Operation and Tools and Shop Products Guide” for tools and supplies
Maintenance Manual, “Capacities (Refill)”. suitable to collect and contain fluids on Caterpillar
products.
6. Remove transmission breather (3) and discard the
transmission breather. Install a new transmission Dispose of all fluids according to local regulations and
breather. mandates.
7. Start the engine and run the engine at low
idle. Inspect the transmission and differential Refer to the Operation and Maintenance Manual,
components for leaks. “Access Doors and Covers” for the location of the
service points.
8. Engage the transmission modulator control
(pedal). Slowly operate the transmission control
lever in order to circulate the oil.

9. With the engine at low idle, maintain the oil level

between the marks on the dipstick. If necessary,
add oil through the filler tube.

10. Stop the engine.

11. Close the access door.

g00930709
Illustration 175

1. Install frame lock pin (1).

132 SEBU7474-03
Maintenance Section
Transmission and Differential Oil Filter and Screens - Replace/Clean

g00795948
Illustration 177

12. Slowly remove the cover for magnetic screen

(6). Slowly remove the cover for supplemental
magnetic screen (7). Allow the oil to drain into a
suitable container.

13. Remove the magnetic screen tube assemblies.

14. Separate the magnets and the tube assemblies

from the screens. Wash the screens and the tube
assemblies in clean nonflammable solvent. Allow
the screens to dry and allow the tube assemblies
to dry.

NOTICE
Do not drop or rap magnets on hard objects, or dam-
age can result. Replace damaged magnets.

g00777843
Illustration 176 15. Clean the magnets with a cloth or clean the
magnets with a firm brush. Allow the magnets to
2. Open drain valve (5) on oil filter housing (4). dry.
3. Loosen pressure test port (2) or oil sample valve 16. Install the magnets and tube assemblies into the
(3) in order to vent oil filter housing (4). screens.
4. Remove oil filter housing (4). 17. Install the screens.
5. Remove the used element and discard the used 18. Inspect the cover seals. If the cover seals are
element. damaged, replace the cover seals.
6. Clean oil filter housing (4) with a clean 19. Install the covers and tighten the bolts.
nonflammable solvent.
20. Start the engine.
7. Clean the base of oil filter housing (4).
21. With the parking brake engaged, run the engine
8. Insert a new filter element into filter housing (4). at low idle in order to circulate the transmission oil.
9. Replace the filter housing base seal. 22. Inspect all of the transmission components for
leaks.
10. Install filter housing (4).

11. Close drain valve (5) on oil filter housing (4).

SEBU7474-03 133
Maintenance Section
Transmission and Differential Oil Level - Check

Clean the area around dipstick/fill cap (1) before you

remove the cap.

1. Run the engine at low idle. Remove cap (1).

Maintain the oil between the “LOW” mark and the
“FULL” mark on the dipstick.

2. If necessary, add oil.

3. Clean cap (1) and install cap (1).

i01863633

Transmission and Differential

Illustration 178 g00986356
Oil Sample - Obtain
23. With the engine at low idle, maintain the oil level SMCS Code: 3006-008; 3030-008; 3080-008;
between the marks on dipstick (8). If necessary, 3258-008; 7542
add the oil through the filler tube .
Refer to the Operation and Maintenance Manual,
24. Stop the engine. “Access Doors and Covers” for the location of the
service points.
25. Remove frame lock pin (1) and store the frame
lock pin.

i01896026

Transmission and Differential

Oil Level - Check
SMCS Code: 3030-535-FLV; 3080-535-FLV;
3258-535-FLV

Hot oil and hot components can cause personal g00950029

injury. Do not allow hot oil or hot components to Illustration 180
contact skin.
The oil sample for the transmission and the
differential should be taken from the sampling valve
Refer to the Operation and Maintenance Manual, above the transmission filter.
“Access Doors and Covers” for the location of the
service points. Refer to Special Publication, SEBU6250, “S·O·S Oil
Analysis” for information that pertains to obtaining a
sample of the transmission and differential oil.

g00986419
Illustration 179
134 SEBU7474-03
Maintenance Section
Wheel Bearing Oil (Front) - Change

i01829992 i01830000

Wheel Bearing Oil (Front) - Wheel Bearing Oil Level (Front)

Change - Check
SMCS Code: 4205-044; 4208-044; 4234-044; SMCS Code: 4205-535-FLV; 4208-535-FLV;
7551-044-WHL 4234-535-FLV; 7551-535-FLV

Clean the surface area around the check/fill plug

before you check the oil level.

g00934106
Illustration 181

The front wheel bearings are located on the inner

side of each front wheel. The check/fill plugs (1) are Illustration 182 g00934106

located on the housings of each front wheel bearing.

1. Remove check/fill plug (1).
Clean the surface around each check/fill plug before
you change the oil. 2. Maintain the oil level to the bottom of the opening
for the check/fill plug. If necessary, add oil.
NOTICE
Care must be taken to ensure that fluids are contained 3. Install plug (1).
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to 4. Repeat Step 1 through Step 3 for the other wheel
collect the fluid with suitable containers before open- bearing.
ing any compartment or disassembling any compo-
nent containing fluids. i01671089

Refer to Special Publication, NENG2500, “Caterpillar Wheel Lean Bar Bearings -

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar Lubricate
products.
SMCS Code: 5225-086-BD
Dispose of all fluids according to local regulations and
mandates. Wipe all the fittings before you apply lubricant to the
fittings.
1. Remove check/fill plug (1).

2. Use a 1U-7683 Suction Gun in order to remove

the oil from the housing for the wheel bearing.

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).

4. Install check/fill plug (1).

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

bearing.
SEBU7474-03 135
Maintenance Section
Wheel Lean Bearings - Lubricate

i01893509

Wheel Lean Cylinder Bearings

- Lubricate
SMCS Code: 5211-086-BD

Wipe all fittings before you apply lubricant to the

fittings.

g00118004
Illustration 183

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
g00985581
Illustration 185

SMCS Code: 5225-086-BD Each end of the wheel lean cylinder has one fitting.
In order to lubricate the bearings for the wheel lean
Wipe all the fittings before you apply lubricant to the cylinder, use 183-3424 Grease Cartridge (5%
fittings. Molybdenum Disulfide) to apply lubricant to the
fittings.

i01834467

Window Washer Reservoir -

Fill
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.
g00115441
Illustration 184
The windshield washer reservoir is positioned in the
Each front wheel has two fittings. In order to lubricate seat support to the left of the operator’s seat.
the wheel lean bearings, use 183-3424 Grease
Cartridge (5% Molybdenum Disulfide) to apply 1. Remove the access cover for the windshield
lubricant to the fittings. washer reservoir.
136 SEBU7474-03
Maintenance Section
Window Wiper - Inspect/Replace

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
g00937113
Illustration 186

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.

5. Install the access cover.

Note: The window washer nozzles can be adjusted

so that the window washer solvent will be sprayed
in the desired direction. g00775840
Illustration 188

i01494015 Use commercially available window cleaning

solutions to clean the windows. Stand on the ground
Window Wiper - in order to clean the outside windows, unless
Inspect/Replace handholds are available.

SMCS Code: 7305-040; 7305-510

g00775786
Illustration 187