SAFETY.CAT.

COM

140M
MOTOR GRADER
Maintenance Intervals

Excerpted from Operation & Maintenance Manual (SEBU7881-02-01)

© 2007 Caterpillar
All Rights Reserved
94 SEBU7881-02
Maintenance Section
Maintenance Interval Schedule

i02663382 Scarifier Teeth - Inspect/Replace ........................ 146

Scarifier Teeth - Inspect/Replace ........................ 147
Maintenance Interval Schedule Window Washer Reservoir - Fill .......................... 157
Window Wiper - Inspect/Replace ........................ 157
SMCS Code: 1000; 7000 Windows - Clean ................................................. 158
Ensure that all safety information, warnings, and Every 10 Service Hours or Daily
instructions are read and understood before any
operation or any maintenance procedures are Backup Alarm - Test .............................................. 97
performed. Brakes, Indicators and Gauges - Test ................. 100
Circle Drive Pinion Teeth - Lubricate .................. 107
The user is responsible for the performance of Circle Top - Lubricate .......................................... 108
maintenance, including all adjustments, the use of Cooling System Coolant Level - Check ............... 112
proper lubricants, fluids, filters, and the replacement Engine Oil Level - Check .................................... 121
of components due to normal wear and aging. Failure Fuel System Water Separator - Drain ................. 130
to adhere to proper maintenance intervals and Seat Belt - Inspect .............................................. 147
procedures may result in diminished performance of Transmission and Differential Oil Level - Check .. 154
the product and/or accelerated wear of components.
Every 100 Service Hours or 2 Weeks
Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST, Articulation Bearings - Lubricate ........................... 96
in order to determine the maintenance intervals. Axle Oscillation Bearings - Lubricate .................... 96
Products that operate in severe operating conditions Belt - Inspect ......................................................... 97
may require more frequent maintenance. Blade Lift Cylinder Socket - Lubricate ................... 99
Cab Air Filter - Clean/Replace ............................ 102
Note: Before each consecutive interval is performed, Centershift Cylinder Socket - Lubricate .............. 103
all maintenance from the previous interval must be Centershift Lock Bar - Clean/Lubricate ............... 103
performed. Drawbar Ball and Socket - Lubricate ................... 117
Fuel Tank Water and Sediment - Drain ............... 131
When Required Hydraulic System Oil Level - Check ................... 135
Kingpin Bearings - Lubricate ............................... 136
All Wheel Drive Motor Supply Hose - Ripper Cylinder Bearings - Lubricate .................. 144
Inspect/Replace .................................................. 96 Scarifier Lift Link Socket - Lubricate ................... 146
Battery - Recycle .................................................. 97 Steering Cylinder Ends and Tie Rods -
Belt - Replace ....................................................... 98 Lubricate ........................................................... 148
Blade Lift Cylinder Socket - Check/Adjust/ Tandem Drive Oil Level - Check ......................... 150
Replace ............................................................... 99 Tire Inflation - Check ........................................... 151
Brake Accumulator - Check ................................ 100 Wheel Bearing Oil Level (Front) - Check ............ 156
Centershift Cylinder Socket - Check/Adjust/ Wheel Lean Bar Bearings - Lubricate ................. 156
Replace ............................................................. 102 Wheel Lean Bearings - Lubricate ....................... 156
Circle Clearances - Check/Adjust ....................... 104 Wheel Lean Cylinder Bearings - Lubricate ......... 157
Circle Drive Oil Level - Check ............................. 107 Work Tool Lift - Lubricate .................................... 158
Circuit Breakers - Reset ...................................... 108
Condenser (Refrigerant) - Clean ........................ 109 Every 250 Service Hours
Cutting Edges and End Bits - Inspect/Replace .... 116
Drawbar Ball and Socket End Play - Cooling System Coolant Sample (Level 1) -
Check/Adjust ...................................................... 117 Obtain ................................................................ 112
Engine Air Filter Primary Element - Clean/
Replace .............................................................. 118 Initial 500 Service Hours (or at first oil
Engine Air Filter Secondary Element - Replace .. 120 change)
Engine Crankcase Breather - Replace ............... 121
Engine Overheating ............................................ 124 Battery or Battery Cable - Inspect/Replace .......... 97
Engine Power Loss ............................................. 125 Electronic Unit Injector - Inspect/Adjust ............... 118
Ether Starting Aid Cylinder - Replace ................. 126 Engine Valve Lash - Check ................................. 125
Fuel System - Fill ................................................ 126
Fuses - Replace .................................................. 131 Initial 500 Hours (for New Systems, Refilled
Moldboard Wear Strip - Inspect/Adjust/Replace .. 137 Systems, and Converted Systems)
Oil Filter - Inspect ................................................ 141
Radiator - Clean .................................................. 143 Cooling System Coolant Sample (Level 2) -
Radiator Core - Clean ......................................... 144 Obtain ................................................................ 113
Receiver Dryer (Refrigerant) - Replace .............. 144
Ripper Tip - Inspect/Replace .............................. 145
SEBU7881-02 95
Maintenance Section
Maintenance Interval Schedule

Every 500 Service Hours or 3 Months Every 4000 Service Hours

Braking System - Test ......................................... 101 Hydraulic System Oil - Change ........................... 134
Engine Oil Sample - Obtain ................................ 121
Engine Oil and Filter - Change ........................... 122 Every 6000 Service Hours or 3 Years
Fuel System - Prime ........................................... 127
Fuel System Primary Filter (Water Separator) Cooling System Coolant Extender (ELC) - Add ... 111
Element - Replace ............................................ 128
Fuel System Secondary Filter - Replace ............ 129 Every 12 000 Service Hours or 6 Years
Fuel Tank Cap and Strainer - Clean ................... 130
Hydraulic System Oil Sample - Obtain ............... 136 Cooling System Coolant (ELC) - Change ........... 109
Oil Filter (Hydraulic Tank Return) - Replace ....... 138
Oil Filter (Implement Controls) - Replace ........... 139
Piston Motor (AWD) Oil Level - Check ................ 142
Piston Motor (AWD) Oil Sample - Obtain ............ 142
Tandem Breather - Clean/Replace ..................... 149
Tandem Drive Oil Sample - Obtain ..................... 150
Transmission and Differential Oil Filter and Screens -
Replace/Clean .................................................. 152
Transmission and Differential Oil Sample -
Obtain ............................................................... 154

Every 1000 Service Hours or 6 Months

Blade Cushion Accumulator - Check .................... 99
Rollover Protective Structure (ROPS) - Inspect .. 145
Transmission and Differential Oil - Change ........ 151

Every 1000 Service Hours or 1 Year

Oil Filter (All Wheel Drive) - Replace .................. 137

Every 2000 Service Hours or 2 Years

Battery or Battery Cable - Inspect/Replace .......... 97
Circle Drive Oil - Change .................................... 106
Cooling System Pressure Cap - Clean/Replace .. 114
Crankshaft Vibration Damper - Inspect ................ 116
Electronic Unit Injector - Inspect/Adjust ............... 118
Engine Valve Lash - Check ................................. 125
Engine Valve Rotators - Inspect ......................... 125
Evaporator Coil and Heater Coil - Clean ............ 126
Piston Motor (AWD) Oil - Change ....................... 141
Tandem Drive Oil - Change ................................ 149
Wheel Bearing Oil (Front) - Change ................... 155

Every Year
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................ 113
Engine Air Filter Primary Element - Clean/
Replace .............................................................. 118

Every 3 Years After Date of Installation or

Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 148

Every 3000 Service Hours or 3 Years

Cooling System Water Temperature Regulator -
Replace .............................................................. 115
96 SEBU7881-02
Maintenance Section
All Wheel Drive Motor Supply Hose - Inspect/Replace

i02525397 i02525595

All Wheel Drive Motor Supply Articulation Bearings -

Hose - Inspect/Replace Lubricate
SMCS Code: 3154-040-YW; 3154-510-YW; SMCS Code: 7057-086-BD
4351-040-YW; 4351-510-YW
Note: Caterpillar recommends the use of 5%
molybdenum grease for lubricating the articulation
bearings. Refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for
Hot oil and hot components can cause personal
more information on molybdenum grease.
injury. Do not allow hot oil or hot components to
contact skin.
Wipe all the fittings before you apply lubricant through
the fittings.

g01263278
Illustration 98
The fittings for the articulation bearings are located on the front
left side of the rear frame.

Apply the appropriate lubricant through fitting (1) for

g01263171 the upper articulation bearing.
Illustration 97
Supply hoses for the all wheel drive motors
Apply the appropriate lubricant through fitting (2) for
the lower articulation bearing.
1. Clean the area around each hose before you
begin inspection.
i02589202
2. Inspect each hose for the following conditions:
Axle Oscillation Bearings -
• Leaks Lubricate
• Wear SMCS Code: 3268; 4313

• Damage Note: Caterpillar recommends the use of 5%

molybdenum grease for lubricating the axle oscillation
3. Correct any leaks. bearings. Refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for
4. Replace any worn hoses. Replace any damaged more information on molybdenum grease.
hoses.
Wipe the fitting before you apply lubricant through
the fitting.
SEBU7881-02 97
Maintenance Section
Backup Alarm - Test

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

g01073624 battery disconnect switch. The battery disconnect
Illustration 99
switch is connected to the machine frame.
The fitting for the axle oscillation bearings is located in the middle
of the front axle.
Note: Do not allow the disconnected battery cable to
contact the battery disconnect switch or the machine.
Apply the appropriate lubricant through the fitting in
order to lubricate the axle oscillation bearings.
4. Disconnect the negative battery cable from the
battery.
i02589228
5. Disconnect the positive battery cable from the
Backup Alarm - Test battery.

SMCS Code: 7406-081 6. Inspect the battery terminals for corrosion. Inspect
the battery cables for wear or damage.
The backup alarm is on the rear of the machine.
7. If necessary, make repairs. If necessary, replace
In order to test the alarm for proper functioning, turn the battery cable or the battery.
the engine start switch to the ON position.
8. Connect the positive battery cable at the battery.
Apply the service brake. Disengage the parking
brake. Move the transmission control switch to a 9. Connect the negative battery cable at the battery.
REVERSE position.
10. Connect the battery cable at the battery
The backup alarm should start to sound immediately. disconnect switch.
The backup alarm will continue to sound until
the transmission control switch is moved to the 11. Install the key for the battery disconnect switch.
NEUTRAL position or to any FORWARD position. Turn the battery disconnect switch to the ON
position.
i00993589

Battery - Recycle i02327582

Belt - Inspect
SMCS Code: 1401-561
SMCS Code: 1357-040; 1397-040
Always recycle a battery. Never discard a battery.
Refer to Operation and Maintenance Manual,
Always return used batteries to one of the following “Access Doors and Covers” for the location of the
locations: service points.

• A battery supplier 1. Stop the engine.

• An authorized battery collection facility 2. Remove the left hand panel and the right hand
panel from the front of the engine enclosure.
• Recycling facility
98 SEBU7881-02
Maintenance Section
Belt - Replace

g01162613 g01162613
Illustration 100 Illustration 101

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. Replace the belt if any of the following conditions tensioner (2) and pry the belt tensioner in a
exist: counterclockwise direction.

• excessive cracking 2. Remove the belt.

• excessive wear 3. Install the new belt around the pulleys.

• excessive damage 4. Inspect the free arm stop of the belt tensioner. The
free arm stop must be aligned with the green zone
5. Inspect the free arm stop of belt tensioner (2). which is on the decal of the belt tensioner.
The free arm stop must be aligned with the green
zone which is on the decal of the belt tensioner. 5. Check the belt tension after 30 minutes of
If the free arm stop is in either of the red zones, operation.
replace the belt.
Note: The break-in period for the belt is considered
to be 30 minutes.
i02327618

Belt - Replace
SMCS Code: 1357-510; 1397-510

Refer to Operation and Maintenance Manual,

“Access Doors and Covers” for the location of the
service points.
SEBU7881-02 99
Maintenance Section
Blade Cushion Accumulator - Check

i02589927 3. Remove bolts (2) from cap (1). Remove cap (1).
Blade Cushion Accumulator - 4. Remove one shim from either side of the inserts in
Check order to reduce clearance.

SMCS Code: 5077-535-BG 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.

i02527187

Illustration 102
g01296656
Blade Lift Cylinder Socket -
Blade cushion accumulators (1) are located on the Lubricate
left side of the front frame.
SMCS Code: 5102-086; 5103-086
Consult your Caterpillar dealer for the correct
checking procedure, the correct filling procedures Note: Caterpillar recommends the use of
and the recommended pressure. 5% molybdenum grease for lubricating the
blade lift cylinder sockets. Refer to Special
Publication, SEBU6250, “Caterpillar Machine
i02527178 Fluids Recommendations” for more information on
molybdenum grease.
Blade Lift Cylinder Socket -
Check/Adjust/Replace Wipe all the fittings before you apply lubricant through
the fittings.
SMCS Code: 5102-025; 5102-510; 5102-535;
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.

g01071490
Illustration 104

There are two blade lift cylinder sockets. Each blade

lift cylinder socket has one fitting.

Apply the appropriate lubricant through fitting (1) in

order to lubricate the blade lift cylinder sockets.

g01071359
Illustration 103
100 SEBU7881-02
Maintenance Section
Brake Accumulator - Check

i02590050 • The correct filling procedure

Brake Accumulator - Check • The recommended pressure
SMCS Code: 4263-535 Your Caterpillar dealer has the appropriate tools
for measuring the precharge pressure of the brake
1. Move the engine start switch to the ON position. accumulators.

Note: Only use dry nitrogen gas to recharge the

brake accumulators.

i02514369

Brakes, Indicators and Gauges

- Test
SMCS Code: 4251-081; 4267-081; 4269-081;
7000-081; 7450-081; 7490-081

g01257893
Illustration 105

Note: Alert indicator (1) will illuminate if the brake

system is not at the normal operating pressure.

2. Start the engine and run the engine for one minute
in order to increase the accumulator pressure.
Alert indicator (1) should turn off. Stop the engine.

3. Apply the service brake pedal and release the

service brake pedal in order to decrease the
accumulator pressure. Apply the service brake
pedal and release the service brake pedal for a Illustration 107
g01257920
minimum of five applications, until alert indicator
(1) illuminates. Look for broken lenses on the gauges, broken
indicator lights or broken switches, etc.

Start the engine. Run the engine until the gauges

have stabilized.

Look for inoperative gauges.

Turn on all of the machine lights. Check for proper

operation.

Sound the horn.

Move the machine forward and test the service

brakes. If the service brakes do not function properly,
g01296741
refer to Operation and Maintenance Manual, “Braking
Illustration 106 System - Test”.
4. If alert indicator (1) illuminates with less than five Stop the engine.
applications of the service brake pedal, measure
the nitrogen precharge pressure of accumulators Make any needed repairs before you operate the
(2). Consult Systems Operation, Testing and machine.
Adjusting, “Brake Accumulator - Test and Charge”
for the following information:

• The correct checking procedure

SEBU7881-02 101
Maintenance Section
Braking System - Test

i02662777 Note: The friction material for the brake may

require replacement. The new friction material for
Braking System - Test the brake may require conditioning for maximum
performance. Consult your Caterpillar dealer or see
SMCS Code: 3077-081; 4011-081; 4250-081; Special Instruction, SEHS9187 for the procedure for
4251-081; 4267-081 conditioning.

Service Brake Holding Ability Test Parking Brake Holding Ability Test

Personal injury can result if the machine moves Personal injury can result if the machine moves
while testing. while testing.
If the machine begins to move during test, reduce It the machine begins to move during test, reduce
the engine speed immediately and engage the the engine speed immediately and engage the ser-
parking brake. vice brake control.

NOTICE NOTICE
If the machine begins to move, reduce the engine If the machine moved while testing the parking brake,
speed immediately and engage the parking brake. consult your Caterpillar dealer.

Have the dealer inspect and, if necessary repair the

NOTICE parking brake before returning the machine to opera-
If the machine moved while testing the service brake tion.
consult your Caterpillar dealer.

Have the dealer inspect and, if necessary, repair the Be sure that the area around the machine is clear of
service brakes before returning the machine to oper- personnel and clear of obstacles.
ation.
Test the parking brake on a hard dry surface.
Make sure that the area around the machine is clear Fasten the seat belt before you test the parking
of personnel and clear of obstacles. brake.
Test the service brake on a dry level surface. Use the following test to determine whether the
parking brake is functional. This test is not intended
Fasten your seat belt before you test the brakes. to measure the maximum holding ability of the
parking brake.
Use the following test in order to determine whether
the service brake is functional. This test is not 1. Position the machine on a slope of 20 percent.
intended to measure the maximum holding ability of
the service brake. 2. Engage the parking brake control. Release the
service brake control. The wheels should not
1. Start the engine. Raise the blade slightly. Depress rotate. If the wheels rotate, engage the service
the transmission modulator control (inching brake control.
pedal). Apply the service brake control.

2. Select the FIFTH SPEED FORWARD position

on the transmission. Set the throttle hold mode
switch to the MANUAL position. Push the top of
the throttle set/accel switch in order to set the
engine speed to high idle.

3. Gradually release the transmission modulator

control (inching pedal). The machine should not
move. The engine should stall.

4. Reduce the engine speed to low idle. Engage

the parking brake control. Lower the blade to the
ground. Stop the engine.
102 SEBU7881-02
Maintenance Section
Cab Air Filter - Clean/Replace

i02638988 5. After you clean the filter element, inspect the filter
element. Do not use a filter element with damaged
Cab Air Filter - Clean/Replace pleats or a damaged seal. If the filter element is
damaged, replace the filter element.
SMCS Code: 7311-070-FI; 7311-510-FI; 7342-070;
7342-510 6. Install the filter element.

7. Install filter cover (2).

8. Turn thumb screws (1) clockwise in order to install

the thumb screws.

Outside Filter
1. Turn thumb screw (4) counterclockwise in order to
remove the thumb screw.

2. Open access cover (3).

3. Remove the filter element. Clean the filter element

g01299060
Illustration 108 with pressure air or wash the filter element in warm
The operator’s seat has been removed for ease of viewing. water and in a nonsudsing household detergent.

4. Rinse the filter element in clean water. Thoroughly

air dry the filter element.

5. After you clean the filter element, inspect the filter

element. Do not use a filter element with damaged
pleats or a damaged seal. If the filter element is
damaged, replace the filter element.

6. Install the filter element.

7. Close access cover (3).

8. Turn thumb screw (4) clockwise in order to install

the thumb screw.
g01323235
Illustration 109

i02103440
The inside cab air filter is located behind the
operator’s seat. The outside cab air filter is located
behind access cover (3).
Centershift Cylinder Socket -
Check/Adjust/Replace
Note: Clean the cab air filters more often in dusty
conditions. SMCS Code: 5223-023; 5223-025; 5223-535

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

Inside Filter 90 degrees to the frame. Lower the blade to the
ground.
1. Turn thumb screws (1) counterclockwise in order
to remove the thumb screws. 2. Operate the centershift cylinder. Observe the
socket. If the socket moves without movement of
2. Remove filter cover (2). the drawbar, adjustment is necessary.
3. Remove the filter element. Clean the filter element
with pressure air or wash the filter element in warm
water and in a nonsudsing household detergent.

4. Rinse the filter element in clean water. Thoroughly

air dry the filter element.
SEBU7881-02 103
Maintenance Section
Centershift Cylinder Socket - Lubricate

g01071500 g01071609
Illustration 110 Illustration 111

3. Remove bolts (1) from cap (2). Remove cap (2). There are two centershift cylinder sockets. Each
centershift cylinder socket has one fitting.
4. Remove one shim from either side of the inserts in
order to reduce clearance. Apply the appropriate lubricant through the fittings in
order to lubricate the centershift cylinder sockets.
Note: If you need to remove two shims, then remove
one shim from each side of the inserts.
i02327869

5. Install the cap and bolts and tighten the bolts. Centershift Lock Bar -
6. Check the socket for movement. If you observe Clean/Lubricate
movement in the socket, repeat Step 3 through
Step 5. SMCS Code: 5221-070; 5221-086

Note: If no shims remain, install new inserts. Install Note: Caterpillar recommends the use of 5%
two shims on each side of the socket. Add additional molybdenum grease for lubricating the centershift
shims, as needed. lock bar. Refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for
more information on molybdenum grease.
i02527356

Centershift Cylinder Socket -

Lubricate
SMCS Code: 5223-086

Note: Caterpillar recommends the use of

5% molybdenum grease for lubricating the
centershift cylinder socket. Refer to Special
Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” for more information on
molybdenum grease.

Wipe all the fittings before you apply lubricant through

g00811486
the fittings. Illustration 112

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.
104 SEBU7881-02
Maintenance Section
Circle Clearances - Check/Adjust

i02327897

Circle Clearances -
Check/Adjust
SMCS Code: 6152-025; 6152-535; 6153-025;
6153-535; 6154-025; 6154-535; 6155-025;
6155-535

Note: In order to improve the accuracy for all

adjustments, remove debris and abrasive material
from the entire blade circle.

Blade Circle and Drawbar

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

g01150053
Personal injury or death can result from blade Illustration 114
falling.
5. Reinstall two bolts in the drawbar without the
retainer plates. Remove the two pusher bolts
2. Lift the blade 10 mm (0.39 inch) off the ground. near the circle drive. Reinstall the pusher bolts
into drawbar (7) without the spacers. Refer to
3. Engage the parking brake. Stop the engine. Illustration 114 for the correct locations. This
ensures that blade circle (6) is properly seated on
the circle shoes.

6. Remove shims (3), spacer plates (4), and drawbar

wear strips (5).

7. Inspect the wear strips. Inspect the drawbar.

Measure the thickness of the drawbar wear strips.
Replace the wear strips if there is uneven wear.
The wear strips should be in complete contact at
all points with the blade circle. If any wear strip
is not in complete contact with the blade circle,
replace the wear strip.

g01141116 8. If the wear strips can be reused, switch wear strip

Illustration 113
(A) with wear strip (C). Switch wear strip (D) with
wear strip (F). This will help keep the wear on the
4. Remove plate retainer bolts (1) and remove
wear strips even.
retainer plates (2).
9. Reinstall the wear strips, spacer plates, and the
shims. Install shims until the shims are flush with
the top surface of the drawbar.

10. Remove the two rear bolts separately.

Immediately after removing one of the bolts, install
the corresponding retainer plate. Install all of the
retainer plates and bolts.

Note: The shims must not be on the top surface of

the drawbar before the retainer plates are installed.
The shims must be within the inside of the pocket.
SEBU7881-02 105
Maintenance Section
Circle Clearances - Check/Adjust

11. Remove the two pusher bolts from the drawbar.

Reinstall the pusher bolts with the spacers.

g01141043
Illustration 117

Illustration 115
g01141311 Note: The engagement of circle pinion (11) and the
circle teeth is affected by the adjustment of circle
12. Measure clearance (X) between the top of blade shoes (9).
circle (6) and the bottom of drawbar wear strips
(5). Maintain a maximum clearance of 0.5 mm 1. Rotate the blade. Place the blade at an angle of
(0.02 inch). 90 degrees to the frame.

Note: Make sure that shoe wear strips (10) are 2. Lower the blade to the ground.
completely seated in circle shoes (9). Shoe mounting
fasteners (8) must be tight. 3. Apply the service brake as you slowly inch the
machine in a forward direction. This will hold a
Note: After all the adjustments have been performed, light load between shoe wear strips (10) for the
the blade circle must rotate freely without binding. front circle shoes and blade circle (6).

13. Lubricate the blade circle and the drawbar. Refer 4. Engage the parking brake. Stop the engine.
to Operation and Maintenance Manual, “Circle
Top - Lubricate” for the proper procedure. 5. Measure clearance (Y) that is between the bottom
flange of the circle pinion and the inner machined
surface of the blade circle. If the clearance is not
Circle Pinion and Circle Teeth within 49.5 to 52.5 mm (1.95 to 2.07 inch), then
adjust the clearance.

g01141365
Illustration 116
g01141357
Illustration 118

6. In order to inspect the shoe wear strips, remove

shoe mounting fasteners (8).

Note: Remove each circle shoe (9) one at a time.

106 SEBU7881-02
Maintenance Section
Circle Drive Oil - Change

7. Inspect the shoe wear strips one at a time. 17. Lubricate the circle pinion and the circle teeth.
Measure the thickness of the shoe wear strips on Refer to Operation and Maintenance Manual,
both contact sides. Replace the shoe wear strips if “Circle Drive Pinion Teeth - Lubricate” for the
there is uneven wear. The shoe wear strips should proper procedure.
be in complete contact at all points with the blade
circle. If any wear strip is not in complete contact
i02517027
with the blade circle, replace the wear strip.

8. Install shoe mounting fasteners (8). Tighten all

Circle Drive Oil - Change
shoe mounting fasteners. SMCS Code: 5207-510-OC
9. Loosen the shoe mounting fasteners by one
quarter turn. Loosen locknuts (12).

Note: Adjust the front circle shoes one at a time. Hot oil and hot components can cause personal
Adjust the clearance equally for each front circle injury. Do not allow hot oil or hot components to
shoe. contact skin.

10. Turn adjusting bolts (13) inward or turn

adjusting bolts (13) outward in order to attain NOTICE
49.5 to 52.5 mm (1.95 to 2.07 inch). Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
Note: If the circle shoes are moved outward, it may ing, adjusting and repair of the product. Be prepared to
be necessary to slowly inch the machine in a forward collect the fluid with suitable containers before open-
direction in order to place a light load between the ing any compartment or disassembling any compo-
wear strips for the front circle shoes and the blade nent containing fluids.
circle.
Refer to Special Publication, NENG2500, “Caterpillar
11. After adjustments have been made to any circle Dealer Service Tool Catalog” for tools and supplies
shoe, check the circle shoes for proper clearance. suitable to collect and contain fluids on Caterpillar
If you cannot attain the correct clearance products.
measurement due to worn front shoe wear strips,
replace the worn shoe wear strips. Then, repeat Dispose of all fluids according to local regulations and
Step 10. mandates.

12. Tighten the shoe mounting fasteners and locknuts

for the front circle shoes.

Note: The adjusting bolts must be tight against

the circle shoes before you tighten the mounting
fasteners and the locknuts.

13. Set all of the circle shoes (front, side, and rear) to
contact the blade circle. There will be no clearance
between the circle shoes and the blade circle.

14. When the pinion clearance is set and the front

circle shoes are in contact with the blade circle,
measure distance (Z) between each wear strip g01070293
and the blade circle. The clearance should be a Illustration 119
maximum of 0.8 mm (0.03 inch). Bottom view of the blade circle

15. Tighten all shoe mounting fasteners (8) to a

torque of 530 ± 70 N·m (390 ± 50 lb ft).

16. Tighten locknuts (12) to a torque of 200 ± 30 N·m

(150 ± 22 lb ft).

Note: After all the adjustments have been performed,

the blade circle must rotate freely without binding.
SEBU7881-02 107
Maintenance Section
Circle Drive Oil Level - Check

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

housing at the front of the circle.

g01070350
Illustration 120
Top view of the blade circle
g01070369
Illustration 121
Note: Clean the area around the drain plug and
clean the area around the check/fill plug before you 1. Remove check/fill plug (1).
remove the plugs.
2. Maintain the oil level to the bottom of the opening
1. Remove drain plug (1). Remove check/fill plug (2). for the check/fill plug.
Allow the oil to drain into a suitable container.
3. Install check/fill plug (1).
2. Clean the drain plug and install the drain plug.

3. Fill the circle drive housing with oil. Refer to the i02527479

following topics: Circle Drive Pinion Teeth -

• Operation and Maintenance Manual, “Lubricant Lubricate
Viscosities”
SMCS Code: 5207-086-PI
• Operation and Maintenance Manual, “Capacities
(Refill)”

4. Clean the check/fill plug and install the check/fill Contact with a moving attachment may cause in-
plug. jury or death.
5. Start the engine. Operate the machine for a few Avoid contact with a moving attachment when lu-
minutes. Check the circle drive housing for leaks. bricating or maintaining the attachment.
6. Stop the engine. Remove the check/fill plug and
check the oil level. Maintain the oil level to the Note: Caterpillar recommends the use of 5%
bottom of the filler opening. If necessary, add oil. molybdenum grease for lubricating the circle drive
pinion teeth. Refer to Special Publication, SEBU6250,
7. Install the check/fill plug. “Caterpillar Machine Fluids Recommendations” for
more information on molybdenum grease.
i02100323 The circle drive pinion teeth are located under the
Circle Drive Oil Level - Check circle drive housing.

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.
108 SEBU7881-02
Maintenance Section
Circle Top - Lubricate

i02519424

Circuit Breakers - Reset

SMCS Code: 1417-529; 1420-529

Refer to Operation and Maintenance Manual,

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

Circuit Breaker Resets – Push the buttons inward

in order to reset the circuit breakers. If the system is
working properly, the buttons will remain depressed.
If the buttons do not stay depressed, check the
appropriate electrical circuit.
g01071611
Illustration 122

1. Clean the dirt and the old lubricant from circle

drive pinion teeth (1) and from blade circle (2).

2. Apply the appropriate lubricant to circle drive

pinion teeth (1) and blade circle (2).

i02103680

Circle Top - Lubricate

SMCS Code: 6154-086-TP

1. Park the machine on a level surface and engage g01260787

Illustration 124
the parking brake.

2. Stop the engine. Lower the blade and any The circuit breaker resets are located in the left front
attachments to the ground. compartment of the machine.

AccuGrade Circuit Breaker (1) – The

accugrade circuit breaker is 20 amp. This
circuit breaker is an attachment.

Transmission/Chassis Control Circuit

Breaker (2) – The transmission/chassis
control circuit breaker is 15 amp.

g01071683
Illustration 123
Keyswitch Circuit Breaker (3) – The
keyswitch circuit breaker is 15 amp.
3. Apply a dry film lubricant to the 5 mm (0.2 inch)
gap between the circle and the drawbar yoke.
Apply the dry film lubricant around the entire circle.
See Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations”, “Dry Film
Lubricant” for further information.
SEBU7881-02 109
Maintenance Section
Condenser (Refrigerant) - Clean

Engine Control Circuit Breaker (4) – The

engine control circuit breaker is 20 amp.

Alternator Circuit Breaker (5) – The

alternator circuit breaker is 150 amp. This
circuit breaker is standard.

g01264532
Illustration 125
Main Circuit Breaker (6) – The main
circuit breaker feeds power to the fuses in Refrigerant condenser (1) is located in front of the
the cab that are turned on with the ignition radiator at the rear of the machine.
key. The main circuit breaker is 80 amp.
1. Open the rear access door on the left side of the
machine.

Load Circuit Breaker (7) – The load circuit 2. Inspect the condenser for debris. If necessary,
breaker feeds power to the fuses in the cab clean the condenser.
that are continuously on. The load circuit
breaker is 80 amp. 3. Use clean water in order to wash off all dust and
dirt from the condenser.

4. Close the access door.

i02527639 i02582519

Condenser (Refrigerant) - Cooling System Coolant (ELC)

Clean - Change
SMCS Code: 1805-070 SMCS Code: 1350-044-NL; 1350-544-NL;
1395-044-NL
NOTICE
If excessively dirty, clean condenser with a brush. To
prevent damage or bending of the fins, do not use a
stiff brush. Personal injury can result from hot coolant, steam
and alkali.
Repair the fins if found defective.
At operating temperature, engine coolant is hot
Refer to Operation and Maintenance Manual, and under pressure. The radiator and all lines
“Access Doors and Covers” for the location of the to heaters or the engine contain hot coolant or
service points. 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.
110 SEBU7881-02
Maintenance Section
Cooling System Coolant (ELC) - Change

Always operate Caterpillar engines with a thermostat

NOTICE because these engines have a shunt design cooling
Do not change the coolant until you read and under- system.
stand the material in the Cooling System Specifica-
tions section. Note: Thermostats can be reused if the thermostats
meet certain test specifications. The tested
thermostats must not be damaged and the tested
NOTICE thermostats must not have an excessive buildup of
Mixing ELC with other products reduces the effective- deposits.
ness of the coolant and shortens coolant life. Use only
Caterpillar products or commercial products that have 1. Stop the engine and allow the engine to cool.
passed the Caterpillar EC-1 specifications for pre-
mixed or concentrate coolants. Use only Caterpillar
Extender with Caterpillar ELC. Failure to follow these
recommendations could result in the damage to cool-
ing systems components.

If ELC cooling system contamination occurs see the

topic Extended Life Coolant (ELC) in the Special Pub-
lication, SEBU6250, “Caterpillar Machine Fluids Rec-
ommendations”.

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 Illustration 126
g01292893
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- 2. Open cover (1).
nent containing fluids.
3. Clean the area around the cooling system
Refer to Special Publication, NENG2500, “Caterpillar pressure cap of any dirt or debris. This must be
Dealer Service Tool Catalog” for tools and supplies done before the cooling system pressure cap can
suitable to collect and contain fluids on Caterpillar be removed.
products.
4. Slowly remove the cooling system pressure cap in
Dispose of all fluids according to local regulations and order to relieve pressure.
mandates.

If the coolant in the machine is changed to Extended

Life Coolant from another type of coolant, see Special
Publication, SEBU6250, “Caterpillar Machine Fluids
Recommendations”, “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
g01264581
reduces the chances of unscheduled downtime. Illustration 127
Failure to replace the thermostat on a regularly
scheduled basis could cause severe engine damage. 5. Open drain valves (2). The drain valves are
located at the left rear of the machine. Allow the
Note: If you are only replacing the thermostat, drain coolant to drain into a suitable container.
the coolant from the cooling system so that the level
of the coolant is below the thermostat housing. 6. Flush the cooling system with clean water until the
draining water is transparent.

7. Close the drain valve.

SEBU7881-02 111
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

8. Add the Extended Life Coolant. Refer to Operation

and Maintenance Manual, “Capacities (Refill)”. NOTICE
Care must be taken to ensure that fluids are contained
Note: Make sure that the cooling system pressure during performance of inspection, maintenance, test-
cap is removed for Steps 9 through 10. ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
9. Start the engine and run the engine until the ing any compartment or disassembling any compo-
thermostat opens and the coolant level stabilizes. nent containing fluids.

10. Maintain the coolant level between the “FULL” Refer to Special Publication, NENG2500, “Caterpillar
mark and the “ADD” mark on the coolant tank. Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
11. Install the cooling system pressure cap. Close products.
cover (1).
Dispose of all fluids according to local regulations and
12. Check the radiator for any external leaks. Check mandates.
for air bubbles in the radiator.

13. Stop the engine. When a Caterpillar Extended Life Coolant (ELC)
is used, an extender must be added to the
cooling system. See Operation and Maintenance
i02582576 Manual, “Maintenance Interval Schedule” for the
proper service interval. The amount of extender is
Cooling System Coolant determined by the cooling system capacity.
Extender (ELC) - Add 1. Stop the engine and allow the engine to cool.
SMCS Code: 1352-045; 1352-535; 1352-544-NL;
1352-544; 1395-081

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 cooling system pressure cap slowly to

relieve pressure only when engine is stopped and g01292893
Illustration 128
cooling system pressure cap is cool enough to
touch with your bare hand. 2. Open cover (1).

Do not attempt to tighten hose connections when 3. Clean the area around the cooling system
the coolant is hot, the hose can come off causing pressure cap of any dirt or debris. This must be
burns. done before the cooling system pressure cap can
be removed.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes. 4. Remove the cooling system pressure cap slowly
in order to relieve the pressure.

5. Drain some coolant from the radiator into a

suitable container. This will allow space for
additional cooling system coolant extender.
112 SEBU7881-02
Maintenance Section
Cooling System Coolant Level - Check

6. In order to add cooling system coolant extender, 1. Maintain the coolant level between the “FULL”
refer to Special Publication, SEBU6250, mark and the “ADD” mark on coolant tank (1).
“Extended Life Coolant (ELC)”. Refer to the table
for the correct amount of Caterpillar Extended
Life Coolant (ELC) Extender that is needed to be
added to the cooling system.

7. Install the cooling system pressure cap. Close

the cover.

i02583693

Cooling System Coolant Level

- Check
SMCS Code: 1350-040-HX; 1350-040;
g01295120
1350-535-FLV; 1350-535; 1353-535-FLV; Illustration 130
1354-535; 1395-082; 1395-535; 1395-535-FLV
2. If necessary, add the appropriate coolant mixture.

3. Open cover (2).

Personal injury can result from hot coolant, steam
4. Clean the area around the filler cap of any dirt or
and alkali.
debris. This must be done before the filler cap can
be removed.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines
5. Remove the filler cap slowly in order to relieve
to heaters or the engine contain hot coolant or
pressure.
steam. Any contact can cause severe burns.
6. Add coolant through the filler tube.
Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool
7. Install the filler cap. Close the cover.
enough to touch with your bare hand.

Do not attempt to tighten hose connections when i02585805

the coolant is hot, the hose can come off causing
burns. Cooling System Coolant
Cooling System Conditioner contains alkali. Avoid
Sample (Level 1) - Obtain
contact with skin and eyes. SMCS Code: 1395-554

Refer to Operation and Maintenance Manual, Note: Obtaining a Coolant Sample (Level 1) is
“Access Doors and Covers” for the location of the optional if the cooling system is filled with Cat
service points. ELC (Extended Life Coolant). Cooling systems that
are filled with Cat ELC should have a Coolant Sample
(Level 2) that is obtained at the recommended interval
that is stated in the Maintenance Interval Schedule.

Note: Obtain a Coolant Sample (Level 1) if the

cooling system is filled with any other coolant
instead of Cat ELC. This includes the following
types of coolants:

• Commercial long life coolants that meet the

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

• Cat Diesel Engine Antifreeze/Coolant (DEAC)

Illustration 129
g01294047
• Commercial heavy-duty antifreeze/coolant
SEBU7881-02 113
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain

• Complete the information on the label for the

NOTICE sampling bottle before you begin to take the
Care must be taken to ensure that fluids are contained samples.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to • Keep the unused sampling bottles stored in plastic
collect the fluid with suitable containers before open- bags.
ing any compartment or disassembling any compo-
nent containing fluids. • Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
Refer to Special Publication, NENG2500, “Caterpillar from any other location.
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar • Keep the lids on empty sampling bottles until you
products. are ready to collect the sample.

Dispose of all fluids according to local regulations and • Place the sample in the mailing tube immediately
mandates. after obtaining the sample in order to avoid
contamination.

NOTICE • Never collect samples from expansion bottles.

Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling. • Never collect samples from the drain for a system.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This Submit the sample for Level 1 analysis.
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both For additional information about coolant analysis, see
dealers and customers. Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” or consult your Caterpillar
Note: Level 1 results may indicate a need for dealer.
Level 2 Analysis.
i02487905

Cooling System Coolant

Sample (Level 2) - Obtain
SMCS Code: 1395-554

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.
g01294622
Illustration 131
Refer to Special Publication, NENG2500, “Caterpillar
Refer to Operation and Maintenance Manual, Dealer Service Tool Catalog” for tools and supplies
“Access Doors and Covers” for the location of the suitable to collect and contain fluids on Caterpillar
service points. products.

Obtain the sample of the coolant as close as possible Dispose of all fluids according to local regulations and
to the recommended sampling interval. In order mandates.
to receive the full effect of S·O·S coolant analysis,
you must establish a consistent trend of data.
In order to establish a pertinent history of data,
perform consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.

Use the following guidelines for proper sampling of

the coolant:
114 SEBU7881-02
Maintenance Section
Cooling System Pressure Cap - Clean/Replace

NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.

Refer to Operation and Maintenance Manual,

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

Obtain the sample of the coolant as close as possible g01292893

Illustration 132
to the recommended sampling interval. Supplies
for collecting samples can be obtained from your The cooling system pressure cap is located on top of
Caterpillar dealer. the engine compartment.

Refer to Operation and Maintenance Manual, 1. Open cover (1).

“Cooling System Coolant Sample (Level 1) - Obtain”
for the guidelines for proper sampling of the coolant. 2. Clean the area around the pressure cap of any dirt
or debris. This must be done before the pressure
Submit the sample for Level 2 analysis. cap can be removed.

Reference: For additional information about coolant 3. Remove the pressure cap slowly in order to relieve
analysis, see Special Publication, SEBU6250, pressure.
“Caterpillar Machine Fluids Recommendations” or
consult your Caterpillar dealer. 4. Inspect the cap and the cap seal for damage,
deposits, and foreign material. Clean the cap
with a clean cloth. Replace the cap if the cap is
i02582582
damaged.
Cooling System Pressure Cap 5. Install the cap. Close the cover.
- Clean/Replace
SMCS Code: 1382-070; 1382-510

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
burns.

Cooling System Conditioner contains alkali. Avoid

contact with skin and eyes.
SEBU7881-02 115
Maintenance Section
Cooling System Water Temperature Regulator - Replace

i02585802

Cooling System Water

Temperature Regulator -
Replace
SMCS Code: 1355-070; 1355-510; 1393-010

Personal injury can result from hot coolant, steam

and alkali.

At operating temperature, engine coolant is hot Illustration 133

g01162907
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or 1. Loosen hose clamp (1) and remove the hose from
steam. Any contact can cause severe burns. the water temperature regulator housing.
Remove filler cap slowly to relieve pressure only 2. Remove bolts (2) from the water temperature
when engine is stopped and radiator cap is cool regulator housing and remove the water
enough to touch with your bare hand. temperature regulator housing.
Do not attempt to tighten hose connections when 3. Remove the gasket and remove the water
the coolant is hot, the hose can come off causing temperature regulators from the water
burns. temperature regulator housing.
Cooling System Conditioner contains alkali. Avoid
contact with skin and eyes. NOTICE
The water temperature regulators may be reused if the
water temperature regulators are within test specifica-
Replace the water temperature regulators on a tions, are not damaged, and do not have excessive
regular basis in order to reduce the chance of buildup of deposits.
unscheduled downtime and of problems with the
cooling system.
NOTICE
The water temperature regulators should be replaced Since Caterpillar engines incorporate a shunt design
after the cooling system has been cleaned. Replace cooling system, it is mandatory to always operate the
the water temperature regulators while the cooling engine with a water temperature regulator.
system is completely drained or while the cooling
system coolant is drained to a level that is below Depending on load, failure to operate with a water
the housing assembly for the water temperature temperature regulator could result in either an over-
regulator. heating or an overcooling condition.

NOTICE NOTICE
Failure to replace the engine’s water temperature reg- If the water temperature regulator is installed incor-
ulator on a regularly scheduled basis could cause se- rectly, it will cause the engine to overheat.
vere engine damage.

4. Install a new water temperature regulator and

Note: If you are only replacing the water temperature a new gasket. Install the water temperature
regulators, drain the cooling system coolant to a level regulator housing.
that is below the housing assembly for the water
temperature regulator. 5. Install the water temperature regulator housing
and the hose. Tighten the hose clamp.

6. Add the cooling system coolant. Refer to Operation

and Maintenance Manual, “Cooling System
Coolant Level - Check” for further information.
116 SEBU7881-02
Maintenance Section
Crankshaft Vibration Damper - Inspect

i02328950 Note: Contact your Caterpillar dealer for further

information.
Crankshaft Vibration Damper
- Inspect i02104012

SMCS Code: 1205-040 Cutting Edges and End Bits -

Damage to the vibration damper or failure of the Inspect/Replace
vibration damper will increase torsional vibrations.
These vibrations will result in damage to the SMCS Code: 6801-040; 6801-510; 6804-040;
crankshaft and to the other engine components. A 6804-510
deteriorating vibration damper will cause excessive
gear train noise at variable points in the speed range.

Personal injury or death can result from the blade

falling.

Block the blade before changing blade tips.

g01071858
Illustration 135
g01162930
Illustration 134
End bits (1) and/or cutting edges (2) may be
Caterpillar recommends replacing vibration damper damaged. The end bits and/or the cutting edges may
(1) for any of the following reasons: be worn excessively. Replace the end bits and/or the
cutting edges, as needed.
• The engine has had a failure because of a broken
crankshaft. 1. Place blocks under the blade. Lower the blade
onto the blocks. Do not block up the blade too
• The S·O·S analysis detected a worn crankshaft high. Just use enough blocks so that the end bits
front bearing. and the cutting edges can be removed.

• The S·O·S analysis detected a large amount of 2. Remove the end bits and/or the cutting edges.
gear train wear that is not caused by a lack of oil.
3. Install new end bits and/or new cutting edges.
• Fluid leakage is detected during inspection.
4. Raise the blade and remove the blocks.
• The housing is damaged.
Refer to Disassembly and Assembly, “Vibration
Damper and Pulley - Remove and Install” for
the procedure to remove the damper and for the
procedure to install the damper.

The vibration damper can be used again if none of

the above conditions are found or if the vibration
damper is not damaged.
SEBU7881-02 117
Maintenance Section
Drawbar Ball and Socket - Lubricate

i02585421

Drawbar Ball and Socket -

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. Illustration 137
g01294408

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

bolster. Move the drawbar backward or move the
machine forward.

g01294398
Illustration 136

Apply the appropriate lubricant through the fitting in

order to lubricate the drawbar ball and socket.

i02585430

Drawbar Ball and Socket End

Play - Check/Adjust
SMCS Code: 6170-025; 6170-535; 6171-025;
6171-535 g01265363
Illustration 138

Check 3. Remove capscrews (7) from cap (3) that holds the
drawbar and adapter (6) together. Remove the
Rotate the blade so that the blade is placed at an adapter.
angle of 90 degrees to the frame. Lower the blade to
the ground. While you maintain a light load between 4. As required, remove shims (4) or install shims
the ball and the socket, inch the machine slowly to (4) in order to attain an end play of 0.6 ± 0.2 mm
the rear. Stop the machine and shut off the engine. (.02 ± .01 inch).

5. Install capscrews (7) in cap (3) and adapter (6).

Rotate cap (3) by hand. The socket should rotate
freely on ball (2).

6. Check the torque on bolts (5) that hold ball (2)

in place. The correct torque is 500 ± 65 N·m
(370 ± 50 lb ft).
118 SEBU7881-02
Maintenance Section
Electronic Unit Injector - Inspect/Adjust

7. Assemble the drawbar to the bolster. Tighten bolts i02460797

(1) to a torque of 950 ± 50 N·m (701 ± 37 lb ft).
Engine Air Filter Primary
i01649392
Element - Clean/Replace
Electronic Unit Injector - SMCS Code: 1051-070-PY; 1051-510-PY;
1054-070-PY; 1054-510-PY
Inspect/Adjust
SMCS Code: 1251-025; 1251-040; 1290-025; NOTICE
1290-040 Service the air cleaner only with the engine stopped.
Engine damage could result.

Service the air cleaner filter element when

Be sure the engine cannot be started while this the Check Engine alert indicator is activated.
maintenance is being performed. To prevent pos- The indicator is located inside the cab. The
sible injury, do not use the starting motor to turn alert indicator will activate when there is an
the flywheel. inlet air restriction, and the Messenger display
will provide a message regarding the specific
Hot engine components can cause burns. Allow problem. Refer to Operation and Maintenance
additional time for the engine to cool before mea- Manual, “Monitoring System” for further
suring/adjusting the unit injectors. information.

The electronic unit injectors use high voltage. Dis- 1. Open the access door for the air filter housing.
connect the unit injector enable circuit connector Refer to Operation and Maintenance Manual,
in order to prevent personal injury. Do not come “Access Doors and Covers”.
in contact with the injector terminals while the en-
gine is running.

NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
ment procedure.

Operation of Caterpillar engines with improper valve

adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life.
g00102316
Illustration 139
The initial adjustment to the unit injector is
recommended at the initial 500 hour interval. The 2. Remove cover (1) for the air filter housing.
unit injector adjustment should then be made at
every 2000 hour interval. The operation of Caterpillar 3. Remove primary filter element (2) from the air
engines with improper adjustments of the electronic filter housing.
unit injector can reduce engine efficiency. This
reduced efficiency could result in excessive fuel 4. Clean the inside of the air filter housing.
usage and/or shortened engine component life.
5. If the machine is equipped with a vacuator valve,
clean the vacuator valve on the cover for the air
filter housing.

6. Install a clean primary air filter element. Install the

cover for the air filter housing.

Note: Refer to “Cleaning Primary Air Filter Elements”.

7. Close the access door.

SEBU7881-02 119
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace

If the alert indicator activates after starting the engine • Vacuum cleaning
or the exhaust smoke is still black after installation of
a clean primary filter element, install a new primary Pressurized Air
filter element. If the alert indicator remains activated,
replace the secondary element. Pressurized air can be used to clean primary air filter
elements that have not been cleaned more than two
Cleaning Primary Air Filter times. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum
Elements pressure of 207 kPa (30 psi).

NOTICE
Caterpillar recommends certified air filter cleaning ser-
vices available at participating Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt to

clean the filter element:

Do not tap or strike the filter element in order to re-

move dust.

Do not wash the filter element.

g00281692
Use low pressure compressed air in order to remove Illustration 140
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the Note: When the primary air filter elements are
pleats and down the pleats from the inside of the filter cleaned, always begin with the clean side (inside)
element. Take extreme care in order to avoid damage in order to force dirt particles toward the dirty side
to the pleats. (outside).

Do not use air filters with damaged pleats, gaskets, or Aim the hose so that the air flows inside the element
seals. Dirt entering the engine will cause damage to along the length of the filter in order to help prevent
engine components. 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.
The primary air filter element can be used up to
six times if the element is properly cleaned and the
element is properly inspected. When the primary Vacuum Cleaning
air filter element is cleaned, check for rips or tears
in the filter material. The primary air filter element Vacuum cleaning is another method for cleaning
should be replaced at least one time per year. This primary air filter elements which require daily cleaning
replacement should be performed regardless of the because of a dry, dusty environment. Cleaning with
number of cleanings. pressurized air is recommended prior to vacuum
cleaning. Vacuum cleaning will not remove deposits
of carbon and oil.
NOTICE
Do not clean the air filter elements by bumping or tap-
ping. This could damage the seals. Do not use ele-
ments with damaged pleats, gaskets, or seals. Dam-
aged elements will allow dirt to pass through. Engine
damage could result.

Visually inspect the primary air filter elements before

cleaning. Inspect the air filter elements for damage
to the seal, the gaskets, and the outer cover. Discard
any damaged air filter elements.

There are two common methods that are used to

clean primary air filter elements:

• Pressurized air
120 SEBU7881-02
Maintenance Section
Engine Air Filter Secondary Element - Replace

Inspecting the Primary Air Filter Do not use paint, a waterproof cover, or plastic as a
protective covering for storage. An air flow restriction
Elements may result. To protect against dirt and damage, wrap
the primary air filter elements in Volatile Corrosion
Inhibited (VCI) paper.

Place the primary air filter element into a box for

storage. For identification, mark the outside of the
box and mark the primary air filter element. Include
the following information:

• Date of cleaning
• Number of cleanings
Store the box in a dry location.

g00281693
Illustration 141
i02488262

Inspect the clean, dry primary air filter element. Use Engine Air Filter Secondary
a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air filter Element - Replace
element. Rotate the primary air filter element. Inspect
the primary air filter element for tears and/or holes. SMCS Code: 1051-510-SE; 1054-510-SE
Inspect the primary air filter element for light that may
show through the filter material. If it is necessary in NOTICE
order to confirm the result, compare the primary air Always replace the secondary element. Do not at-
filter element to a new primary air filter element that tempt to reuse it by cleaning. Engine damage could
has the same part number. result.

Do not use a primary air filter element that has any

Refer to Operation and Maintenance Manual,
tears and/or holes in the filter material. Do not use
“Access Doors and Covers” for the location of the
a primary air filter element with damaged pleats,
service points.
gaskets or seals. Discard damaged primary air filter
elements.
Note: Replace the engine air filter secondary element
when you service the engine air filter primary element
Storing Primary Air Filter Elements for the third time. Replace the secondary element
if the exhaust smoke remains black and a clean
If a primary air filter element that passes inspection primary element has been installed. Also, replace
will not be used, the primary air filter element can the secondary element if the element has been in
be stored for future use. service for one year.

1. Open the access door for the air filter housing.

Remove the air cleaner cover and the primary
element.

g00281694
Illustration 142

g00039214
Illustration 143
SEBU7881-02 121
Maintenance Section
Engine Crankcase Breather - Replace

2. Remove the secondary element.

3. Cover the air inlet opening. Clean the inside of

the air cleaner housing.

4. Uncover the air inlet opening. Install a new

secondary element.

5. Install the primary element and the air cleaner

cover.

6. Close the access door.

i01632265
g01294504
Engine Crankcase Breather - Illustration 144

Replace 2. Before starting the engine, check oil level gauge

(2). Maintain the oil level between the marks on
SMCS Code: 1317-510 the oil level gauge.

Only replace the engine crankcase breather when 3. If necessary, remove oil filler cap (1) in order to
you rebuild the engine. add oil.

4. Clean the oil filler cap and install the oil filler cap.
i02585632
5. Close the access door.
Engine Oil Level - Check
SMCS Code: 1000-535-FLV; 1302-535-FLV; i02586978
1326-535-OC; 1326-535-FLV; 1348-535-FLV
Engine Oil Sample - Obtain
SMCS Code: 1348-008; 1348-554-SM; 7542-008;
7542-554-OC, SM
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact skin.

Hot oil and hot components can cause personal

NOTICE injury. Do not allow hot oil or hot components to
Do not under fill or overfill engine crankcase with oil. contact skin.
Either condition can cause engine damage.

NOTICE
Refer to Operation and Maintenance Manual, Care must be taken to ensure that fluids are contained
“Access Doors and Covers” for the location of the during performance of inspection, maintenance, test-
service points. ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
Clean the area around the oil level gauge and clean ing any compartment or disassembling any compo-
the area around the oil filler cap before you remove nent containing fluids.
the oil level gauge and before you remove the oil
filler cap. Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
1. Open the front left access door. suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

Refer to Operation and Maintenance Manual,

“Access Doors and Covers” for the location of the
service points.
122 SEBU7881-02
Maintenance Section
Engine Oil and Filter - Change

Abnormally harsh operating cycles or harsh

environments can shorten the service life of
the engine oil. Arctic temperatures, corrosive
environments, or extremely dusty conditions may
require a reduction in engine oil change intervals
from the recommendations in Table 9. Also refer
to Special Publication, SEBU5898, “Cold Weather
Recommendations”. Poor maintenance of air filters
or of fuel filters requires reduced oil change intervals.
See your Caterpillar dealer for more information if this
product will experience abnormally harsh operating
cycles or harsh environments.

Table 9

g01295216 Engine Oil Change Interval(1)

Illustration 145
Operating Conditions
The sampling valve for the engine oil is located on
Severe
the right side of the engine compartment.
Multigrade High Fuel Altitude
Refer to Special Publication, SEBU6250, “Caterpillar Oil Type Normal(2) Load Sulfur above
Machine Fluids Recommendations”, “S·O·S Services Factor(3) from 1830 m
Oil Analysis” for information that pertains to obtaining 0.3% to (6000 ft)
a sample of the engine oil. Refer to Special 0.5%(4)
Publication, PEHP6001, “How To Take A Good Oil Cat DEO
Sample” for more information about obtaining a 500 hr 500 hr 500 hr 250 hr(6)
Preferred
sample of the engine oil.
Cat ECF-1
11.0
i02584933 minimum 500 hr 500 hr 500 hr 250 hr(6)
TBN(4)
Engine Oil and Filter - Change Preferred
Cat ECF-1
SMCS Code: 1302-044-OC; 1308-510; 1318-510; TBN(4) 500 hr 500 hr 250 hr(5) 250 hr(6)
1326-535-OC; 1348-044 below 11.0
API CG-4 500 hr 250 hr(5) 250 hr(5) 250 hr(6)
Selection of the Oil Change Interval (1) The traditional oil change interval for engines is 250 hours.
The standard oil change interval in this machine is 500 hours, if
NOTICE the operating conditions and recommended oil types that are
listed in this table are met. Improvements in the engine allow
A 500 hour engine oil change interval is available, pro- this engine oil change interval. This new standard interval is not
vided that the operating conditions and recommend- permitted for other machines. Refer to the applicable Operation
ed multigrade oil types are met. When these require- and Maintenance Manuals for the other machines.
ments are not met, shorten the oil change interval (2) Normal conditions include these factors: Fuel sulfur below

to 250 hours, or use an S·O·S Services oil sampling 0.3%, altitude below 1830 m (6000 ft), and good air filter and
fuel filter maintenance. Normal conditions do not include high
and analysis program to determine an acceptable oil load factor, harsh operating cycles, or harsh environments.
change interval. (3) High load factors can shorten the service life of your engine
oil. Continuous heavy load cycles and very little idle time result
If you select an interval for oil and filter change that is in increased fuel consumption and oil contamination. These
too long, you may damage the engine. factors deplete the oil additives more rapidly. If the average
fuel consumption of your machine exceeds 24 L (6.4 US gal)
per hour, follow the “High Load Factor” recommendations in
Table 9. To determine average fuel consumption, measure
Caterpillar oil filters are recommended. average fuel consumption for a period of 50 to 100 hours. If
the application of the machine is changed, the average fuel
Recommended multigrade oil types are listed in consumption may change.
Table 9. Do not use single grade oils. (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.
SEBU7881-02 123
Maintenance Section
Engine Oil and Filter - Change

Adjustment of the Oil Change

Interval NOTICE
Care must be taken to ensure that fluids are contained
Note: Your Caterpillar dealer has additional during performance of inspection, maintenance, test-
information on these programs. 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-
Program A nent containing fluids.
Verification for an Oil Change Interval of 500 Refer to Special Publication, NENG2500, “Caterpillar
Hours Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
This program consists of three oil change intervals of products.
500 hours. Oil sampling and analysis is done at 250
hours and 500 hours for each of the three intervals Dispose of all fluids according to local regulations and
for a total of six oil samples. The analysis includes mandates.
oil viscosity and infrared (IR) analysis of the oil. If
all of the results are satisfactory, the 500 hour oil
change interval is acceptable for the machine in that NOTICE
application. Repeat Program A if you change the Do not under fill or overfill engine crankcase with oil.
application of the machine. Either condition can cause engine damage.

If a sample does not pass the oil analysis, take one

of these actions: Refer to Operation and Maintenance Manual,
“Access Doors and Covers” for the location of the
• Shorten the oil change interval to 250 hours. service points.

• Proceed to Program B. Park the machine on a level surface and engage the
parking brake. Stop the engine.
• Change to a preferred oil type in Table 9.
Note: Drain the crankcase while the oil is warm. This
allows waste particles that are suspended in the oil to
Program B drain. As the oil cools, the waste particles will settle
to the bottom of the crankcase. The particles will not
Optimizing Oil Change Intervals be removed by draining the oil and the particles will
recirculate in the engine lubrication system with the
Begin with a 250 hour oil change interval. The oil new oil.
change intervals are adjusted by increments. Each
interval is adjusted an additional 50 hours. Periodic oil
sampling and analysis is done during each interval.
The analysis includes oil viscosity and infrared (IR)
analysis of the oil. Repeat Program B if you change
the application of the machine.

If an oil sample does not pass the analysis, shorten

the oil change interval, or change to a preferred
multigrade oil type in the listing above.

Procedure for Changing the Engine

Oil and Filter
g01265545
Illustration 146

Hot oil and hot components can cause personal 1. Open crankcase drain valve (1). Allow the oil to
injury. Do not allow hot oil or hot components to drain into a suitable container.
contact skin.
2. Close crankcase drain valve (1).
124 SEBU7881-02
Maintenance Section
Engine Overheating

g01294218 g01294219
Illustration 147 Illustration 148

3. Open the right side access door. 9. Clean the area around oil filler cap (3) before you
remove the oil filler cap. Clean the area around oil
4. Clean the area around engine oil filter (2) before level gauge (4) before you remove the oil level
you remove the engine oil filter. Remove the gauge. Remove the oil filler cap. Fill the crankcase
engine oil filter with a strap type wrench. Refer with new oil. Refer to the following topics:
to Operation and Maintenance Manual, “Oil Filter
- Inspect”. • Operation and Maintenance Manual, “Lubricant
Viscosities”
5. Clean the base of the engine oil filter housing.
Make sure that all of the old filter gasket is • Operation and Maintenance Manual, “Capacities
removed. (Refill)”

6. Apply a thin film of engine oil to the gasket of the 10. Clean the filler cap and install the filler cap.
new filter.
11. Start the engine and allow the oil to warm. Check
7. Install the new filter by hand until the seal of the the engine for leaks.
filter contacts the base. Note the position of the
index marks on the filter in relation to a fixed point 12. Check the oil level. If necessary, add oil. Refer to
on the filter base. Operation and Maintenance Manual, “Engine Oil
Level - Check” for more information.
Note: There are rotation index marks on the filter
that are spaced 90 degrees or 1/4 of a turn away 13. Stop the engine. Close all access doors.
from each other. When you tighten the filter, use the
rotation index marks as a guide.
i02210900

8. Tighten the filter according to the instructions

that are printed on the filter. Use the index marks
Engine Overheating
as a guide. For non-Caterpillar filters, use the SMCS Code: 1000; 1350; 1353
instructions that are provided with the filter.
If your machine experiences an engine overheating
Note: You may need to use a Caterpillar strap problem, perform the following maintenance
wrench, or another suitable tool, in order to turn procedures in the order that is listed:
the filter to the amount that is required for final
installation. Make sure that the installation tool does 1. Operation and Maintenance Manual, “Cooling
not damage the filter. System Coolant Level − Check”

2. Operation and Maintenance Manual, “Radiator -

Clean”

3. Operation and Maintenance Manual, “Belt -

Inspect”

4. Operation and Maintenance Manual, “Belt -

Replace”
SEBU7881-02 125
Maintenance Section
Engine Power Loss

5. Operation and Maintenance Manual, “Cooling

System Pressure Cap - Clean/Replace” NOTICE
Only qualified service personnel should perform this
6. Operation and Maintenance Manual, “Radiator maintenance. Refer to the Service Manual or your
Core - Clean” Caterpillar dealer for the complete valve lash adjust-
ment procedure.
7. Operation and Maintenance Manual, “Cooling
System Water Temperature Regulator - Replace” Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This re-
If the engine overheating problem is not corrected, duced efficiency could result in excessive fuel usage
consult your Caterpillar dealer. and/or shortened engine component life.

i02488454
NOTICE
Engine Power Loss Do not use the yoke that comes out of the front of the
engine in order to turn over the engine. Damage to the
SMCS Code: 1000; 1051; 1250 crankshaft vibration damper can occur.

If your machine experiences an engine power loss, The adjustment is necessary due to the initial wear of
perform the following maintenance procedures in the the valve train components and to the seating of the
order that is listed: valve train components.
1. Operation and Maintenance Manual, “Engine Air This maintenance is recommended by Caterpillar
Filter Primary Element - Clean/Replace” as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
2. Operation and Maintenance Manual, “Engine Air life.
Filter Secondary Element - Replace”
Ensure that the engine is stopped before you
3. Operation and Maintenance Manual, “Fuel Tank measure the valve lash. To obtain an accurate
Water and Sediment - Drain” measurement, allow the valves to cool before you
perform this maintenance.
4. Operation and Maintenance Manual, “Fuel Tank
Cap and Strainer - Clean” Remove the cover in order to access the rear of
the engine. Check the valve lash. For the correct
5. Operation and Maintenance Manual, “Fuel adjustment procedure, refer to Systems Operation,
System Primary Filter (Water Separator) Element Testing and Adjusting, “Engine Valve Lash -
- Replace” Inspect/Adjust”.
6. Operation and Maintenance Manual, “Fuel System
Secondary Filter - Replace” i00128925

If the problem with engine power loss is not corrected, Engine Valve Rotators - Inspect
consult your Caterpillar dealer.
SMCS Code: 1109-040

i01498587

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

Ensure that the engine can not be started while Inspect the engine valve rotators after the valve
this maintenance is being performed. To help pre- clearances have been set.
vent possible injury, do not use the starting motor
to turn the flywheel. 1. Start the engine and run the engine at low idle.

Hot engine components can cause burns. Allow 2. Watch the top surface of each valve rotator. When
additional time for the engine to cool before mea- the intake valve or the exhaust valve closes, the
suring/adjusting valve lash clearance. engine valve rotator should turn slightly.
126 SEBU7881-02
Maintenance Section
Ether Starting Aid Cylinder - Replace

If an intake valve or an exhaust valve fails to rotate, 2. Remove the seat base.
consult your Caterpillar Dealer.
3. Remove the top cover.
i02585325

Ether Starting Aid Cylinder -

Replace
SMCS Code: 1456-510-CD

Refer to Operation and Maintenance Manual,

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

g01102120
Illustration 150

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

If necessary, replace both coils.

5. Install the top cover.

6. Install the seat base.

7. Install the seat.

g01294347
Illustration 149 Note: If you are operating the machine under harsh
conditions or with the cab door open, it may be
1. Open the right side access door. necessary to clean the coils more often.

2. Loosen the retaining clamp on ether starting aid

cylinder (1). Remove the empty ether starting aid i02650827

cylinder. Properly discard the empty ether starting

aid cylinder.
Fuel System - Fill
SMCS Code: 1250-544
3. Remove the used gasket. Install the new gasket
that is provided with each new ether starting aid
cylinder.

4. Install the new ether starting aid cylinder. Tighten Personal injury or death may result from failure to
the ether starting aid cylinder hand tight. Tighten adhere to the following procedures.
the retaining clamp on the ether starting aid
cylinder securely. Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire.
5. Close the access door.
Clean up all leaked or spilled fuel. Do not smoke
while working on the fuel system.
i02591928

Turn the disconnect switch OFF or disconnect the

Evaporator Coil and Heater battery when changing fuel filters.
Coil - Clean
SMCS Code: 7309-070; 7343-070

The evaporator coil and the heater coil are located

under the seat in the cab.

1. Remove the seat from the seat base.

SEBU7881-02 127
Maintenance Section
Fuel System - Prime

Machines that are Equipped with a

NOTICE Fast Fill Fuel Arrangement
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 NOTICE
to collect the fluid with suitable containers before Use only a Caterpillar approved fast fill system to fuel
opening any compartment or disassembling any com- machines. Over pressurization may cause tank defor-
ponent containing fluids. mation and fuel spillage.

Dispose of all fluids according to local regulations and Contact your Cat dealer for fast fill system availability.
mandates.

Reference: Refer to Operation and Maintenance

Manual, “Capacities (Refill)” for the fuel tank capacity
of your machine.

g01289047
Illustration 152

1. Park the machine on a level surface.

2. Remove dust cover (3).

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.

g01331302
Note: Prime the fuel system. Refer to Operation and
Illustration 151 Maintenance Manual, “Fuel System - Prime” for more
information.
1. Clean filler cap (1) and the surrounding area.

2. Remove the filler cap. i02096133

3. Fill fuel tank (2) with fuel. Fuel System - Prime

4. Install the filler cap. SMCS Code: 1250-548; 1258-548

Note: Prime the fuel system. Refer to Operation and NOTICE

Maintenance Manual, “Fuel System - Prime” for more Do not allow dirt to enter the fuel system. Thoroughly
information. clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.

1. Turn the engine start switch to the ON position.

Leave the engine start switch in the ON position
for two minutes.

2. Verify that the water separator is full of fuel.

128 SEBU7881-02
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

3. If the water separator is not full of fuel, turn the

engine start switch OFF and then turn the engine
start switch ON. This will cycle the fuel priming
pump again.

4. When the water separator is full of fuel, attempt

to start the engine. If the engine starts and the
engine runs rough or the engine misfires, operate
at low idle until the engine is running smoothly.
If the engine cannot be started, or if the engine
continues to misfire or smoke, repeat Step 1.

i02585142

Fuel System Primary Filter Illustration 153

g01294251

(Water Separator) Element -

The primary fuel filter is located inside the engine
Replace compartment on the left side of the machine.
SMCS Code: 1263-510-FQ 1. In order to drain the primary fuel filter, open drain
valve (3) on water separator bowl (2). The water
separator bowl is under primary fuel filter (1).
Catch the fuel in a suitable container.
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. 2. Remove primary fuel filter (1) and water separator
bowl (2). Clean the filter housing base.
Turn the disconnect switch OFF when draining
and/or removing any fuel system components. 3. Remove the water separator bowl from the
primary fuel filter.

NOTICE Note: Check the water separator bowl for damage.

Care must be taken to ensure that fluids are contained Reuse the water separator bowl if no damage is
during performance of inspection, maintenance, test- present.
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- 4. Clean the water separator bowl and clean the
ing any compartment or disassembling any compo- groove for the O-ring. Wash the water separator
nent containing fluids. bowl in a clean nonflammable solvent. Use
pressure air to dry the water separator bowl.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies 5. Lubricate the O-ring with clean diesel fuel or
suitable to collect and contain fluids on Caterpillar lubricate the O-ring with clean motor oil. Place the
products. O-ring in the groove on the water separator bowl.

Dispose of all fluids according to local regulations and 6. Install the clean water separator bowl onto a new
mandates. filter by hand.

7. Apply clean diesel fuel to the seal of the new filter.

NOTICE
Do not fill the fuel filters with fuel before installing the 8. Install the new filter hand tight until the seal of the
fuel filters. The fuel will not be filtered and could be filter contacts the filter mounting base. Note the
contaminated. Contaminated fuel will cause acceler- position of the index marks on the filter in relation
ated wear to fuel system parts. to a fixed point on the filter mounting base.

Refer to Operation and Maintenance Manual, Note: There are rotation index marks on the filter
“Access Doors and Covers” for the location of the that are spaced 90 degrees or 1/4 of a turn away
service points. from each other. When you tighten the filter, use the
rotation index marks as a guide.
SEBU7881-02 129
Maintenance Section
Fuel System Secondary Filter - Replace

9. Tighten the filter according to the instructions that

are printed on the filter. Use the index marks as a NOTICE
guide for tightening the filter. For non-Caterpillar Do not fill fuel filters with fuel before installing them.
filters, use the instructions that are provided with Contaminated fuel will cause accelerated wear to fuel
the filter. system parts.

Note: You may need to use a Caterpillar strap

wrench, or another suitable tool, in order to turn Refer to Operation and Maintenance Manual,
the filter to the amount that is required for final “Access Doors and Covers” for the location of the
installation. Make sure that the installation tool does service points.
not damage the filter.

10. Prime the fuel system. See Operation and

Maintenance Manual, “Fuel System - Prime” for
the proper procedure.

Note: The secondary fuel filter should also be

changed at this time. See Operation and Maintenance
Manual, “Fuel System Secondary Filter - Replace” for
further instructions.

11. Start the engine and check for leaks.

12. Close the access door.

g01294261
Illustration 154
i02585151
The secondary fuel filter is located inside the engine
Fuel System Secondary Filter - compartment on the left side of the machine.
Replace
1. Remove secondary fuel filter (1).
SMCS Code: 1261-510-SE
2. Drain the fuel from the secondary fuel filter into a
suitable container.

3. Clean the mounting base for the secondary fuel

Fuel leaked or spilled onto hot surfaces or electri- filter. Make sure that you remove all of the old seal.
cal components can cause a fire.
4. Apply clean diesel fuel to the seal of the new filter.
Turn the disconnect switch OFF when draining
and/or removing any fuel system components. 5. Install the new filter by hand until the seal of the
filter contacts the base. Note the position of the
NOTICE index marks on the filter in relation to a fixed point
Care must be taken to ensure that fluids are contained on the filter base.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to Note: There are rotation index marks on the filter
collect the fluid with suitable containers before open- that are spaced 90 degrees or 1/4 of a turn away
ing any compartment or disassembling any compo- from each other. When you tighten the filter, use the
nent containing fluids. rotation index marks as a guide.

Refer to Special Publication, NENG2500, “Caterpillar 6. Tighten the filter according to the instructions
Dealer Service Tool Catalog” for tools and supplies that are printed on the filter. Use the index marks
suitable to collect and contain fluids on Caterpillar as a guide. For non-Caterpillar filters, use the
products. instructions that are provided with the filter.

Dispose of all fluids according to local regulations and Note: You may need to use a Caterpillar strap
mandates. wrench, or another suitable tool, in order to turn
the filter to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filter.
130 SEBU7881-02
Maintenance Section
Fuel System Water Separator - Drain

7. Prime the fuel system. See Operation and 1. Open drain (1) and allow the water and sediment
Maintenance Manual, “Fuel System - Prime” for to drain into a suitable container.
the proper procedure.
2. Close the drain.
8. Close the access door.
3. Close the access door.
i02585159

Fuel System Water Separator

i02650845

- Drain Fuel Tank Cap and Strainer -

Clean
SMCS Code: 1263-543
SMCS Code: 1273-070-STR; 1273-070-Z2

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire.

Turn the disconnect switch OFF when draining

and/or removing any fuel system components.

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

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
g01331323
Illustration 156
Dispose of all fluids according to local regulations and
mandates. 1. Clean fuel tank cap (1) and the surrounding area.

Refer to Operation and Maintenance Manual, 2. Remove the fuel tank cap and disassemble the
“Access Doors and Covers” for the location of the fuel tank cap.
service points.
3. Inspect the seal on the fuel tank cap for damage.
If the seal is damaged, replace the seal. Lubricate
the seal on the fuel tank cap.

4. Replace the element on the fuel tank cap.

5. Remove the strainer from the filler opening.

6. Wash the strainer in clean nonflammable solvent.

7. Install the strainer.

8. Install the fuel tank cap.

g01294267
Illustration 155

The fuel system water separator is located inside the

engine compartment on the left side of the machine.
SEBU7881-02 131
Maintenance Section
Fuel Tank Water and Sediment - Drain

i02530037

Fuel Tank Water and Sediment

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

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire.

Turn the disconnect switch OFF when draining

and/or removing any fuel system components.
g01265860
Illustration 158

NOTICE Note: If you need to flush the fuel sump, use drain
Care must be taken to ensure that fluids are contained valve (2) which is located at the bottom of the fuel
during performance of inspection, maintenance, test- tank behind the right tandem housing.
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- i02598641
nent containing fluids.
Fuses - Replace
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies SMCS Code: 1417-510
suitable to collect and contain fluids on Caterpillar
products. Fuses – Fuses protect the electrical system from
damage that is caused by overloaded circuits.
Dispose of all fluids according to local regulations and Replace the fuse if the element is separated. Check
mandates. 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-

cal problem may exist. Consult your Caterpillar dealer.

g01265849
Illustration 157

Drain valve (1) is located at the bottom of the fuel

tank behind the left tandem housing.

1. Open the drain valve. Drain the water and

sediment into a suitable container.

2. Close the drain valve.

g01265895
Illustration 159
132 SEBU7881-02
Maintenance Section
Fuses - Replace

There are two fuse panels. The fuse panels are

positioned to the left side of the operator on the cab Spare (10) – 10 amp
floor.

Lighter (11) – 10 amp

Radio (12) – 15 amp

Communication Radio (13) – 20 amp

g01113131
Illustration 160 Product Link (14) – 10 amp
Fuse panel (1)

Spare (1) – 15 amp

Dome Lamp (15) – 10 amp

Spare (2) – 10 amp

Implement Control (16) – 15 amp

Implement Control 2 (3) – 15 amp

Steering (17) – 10 amp

Horn (4) – 10 amp

Secondary Condenser Fan (18) – 15 amp

Backlight (5) – 10 amp

Air Filter (19) – 15 amp

Monitoring (6) – 10 amp

Primary Condenser Fan (20) – 15 amp

All Wheel Drive (AWD) Controller (7) –

15 amp

Spare (8) – 10 amp

Implement Control 3 (9) – 15 amp

SEBU7881-02 133
Maintenance Section
Fuses - Replace

Rear Work Lights (30) – 15 amp

Heated Mirror (31) – 10 amp

Autolube System (32) – 10 amp

Right Door Wiper (33) – 15 amp

g01114786
Illustration 161
Fuse panel (2)

Front Windshield Wiper and Rear Backup Alarm (34) – 10 amp

Windshield Wiper (21) – 15 amp

Cab Floodlights (35) – 15 amp

Side Windshield Wiper (22) – 15 amp

Centershift and Blade Cushion (36) – 10
amp

Turn Signals (23) – 10 Amp

Primary Blade Work Lights (24) – 15 amp Sensor Power (37) – 10 amp

Work Area Vision System (WAVS) (25) – Seat (38) – 15 amp

10 amp

Heating and Air Conditioning System Differential Lock (39) – 10 amp

(26) – 15 amp

Left Door Wiper (40) – 15 amp

Beacon (27) – 10 amp

Defrost Fan (28) – 10 amp

Secondary Blade Work Lights (29) – 10

amp
134 SEBU7881-02
Maintenance Section
Hydraulic System Oil - Change

i02581782

Hydraulic System Oil - Change

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

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

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.
g01293895
Illustration 162
Note: If the hydraulic oil is not being monitored by the
Caterpillar S·O·S Services program or an equivalent 1. Open cover (1).
oil sampling program, change the hydraulic oil at
every 2000 service hour interval. 2. Clean the area around the hydraulic oil filler cap of
any dirt or debris. This must be done before the
hydraulic oil filler cap can be removed.

3. Slowly remove the hydraulic oil filler cap in order

Hot oil and hot components can cause personal to relieve the tank pressure.
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 the front

wheel 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 system oil tank is positioned behind

the left rear access door on the machine.

g01163329
Illustration 163

4. Open drain valve (2). Drain the oil into a suitable

container.

5. Close the drain valve. Clean the area around the

drain valve.
SEBU7881-02 135
Maintenance Section
Hydraulic System Oil Level - Check

6. Replace the filters for the hydraulic system oil. See

Operation and Maintenance Manual, “Oil Filter
(Hydraulic Tank Return) - Replace” and Operation
and Maintenance Manual, “Oil Filter (Implement
Controls) - Replace” for the proper procedures.

7. Remove the filler screen from the filler tube in the

hydraulic oil tank. Wash the filler screen in clean
nonflammable solvent. Allow the filler screen to
dry.

8. Install the filler screen.

g01293902
Illustration 165

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

sight gauge (5). 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.

17. Stop the engine.

g01163333
Illustration 164
18. If necessary, tighten any loose clamps and tighten
9. Loosen hose clamp (3) on each side of breather any loose connections. Replace any damaged
(4) and remove breather (4). hoses.

10. Wash the breather in clean nonflammable solvent.

i02583248

11. Install the clean breather, and reattach the hose.

Tighten the hose clamps.
Hydraulic System Oil Level -
Check
12. Fill the hydraulic system oil tank. See Operation
and Maintenance Manual, “Capacities (Refill)”. SMCS Code: 5050-535-FLV; 5056-535-FLV;
5095-535-FLV; 7479-535
13. Inspect the filler cap gasket. If the filler cap gasket
is damaged, replace the filler cap gasket.

14. Install the hydraulic oil filler cap. Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
15. Start the engine. Run the engine for a few contact skin.
minutes.

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.
136 SEBU7881-02
Maintenance Section
Hydraulic System Oil Sample - Obtain

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

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

g01263224
Illustration 166

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

sight gauge (2).

2. If necessary, add oil. Open cover (1).

3. Clean the area around the hydraulic oil filler cap of

any dirt or debris. This must be done before the
hydraulic oil filler cap can be removed.
g01267459
Illustration 167
4. Slowly remove the hydraulic oil filler cap in order
to relieve the tank pressure. Hydraulic oil sampling valve (1) is located under the
left rear of the machine.
5. Add oil through the filler tube.
Refer to Special Publication, SEBU6250, “S·O·S
6. Clean the filler cap and install the filler cap. Services Oil Analysis” for information that pertains
to obtaining a sample of the hydraulic oil. Refer
to Special Publication, PEHP6001, “How To Take
i02533919
A Good Oil Sample” for more information about
Hydraulic System Oil Sample obtaining a sample of the hydraulic oil.

- Obtain
i02534310
SMCS Code: 4129-008; 5050-008; 5056-008;
5095-008; 5095-SM
Kingpin Bearings - Lubricate
SMCS Code: 4314-086

Note: Caterpillar recommends the use of 5%

Hot oil and hot components can cause personal molybdenum grease for lubricating the kingpin
injury. Do not allow hot oil or hot components to bearings. Refer to Special Publication, SEBU6250,
contact skin. “Caterpillar Machine Fluids Recommendations” for
more information on molybdenum grease.

Wipe all the fittings before you apply lubricant through

the fittings.
SEBU7881-02 137
Maintenance Section
Moldboard Wear Strip - Inspect/Adjust/Replace

5. Start the engine. Sideshift the blade through

the entire limit of travel. Measure the clearance
between the wear strips and the blade at four
equally spaced points. This will allow you to
determine the location of the minimum clearance.

6. Sideshift the blade to the location of the minimum

clearance.

7. Stop the engine.

8. Tighten the set screws in order to obtain

0.13 to 0.89 mm (0.005 inch to 0.035 inch)
clearance between the moldboard rail and the
g01267710
wear strips at the location of minimum clearance.
Illustration 168
The wheel has been removed for ease of viewing. 9. Tighten the locknuts on the set screws.
Refer to Specifications, SENR3130, “Torque
Each front wheel has a kingpin. Each kingpin has two Specifications” for the recommended torque.
fittings. Apply the appropriate lubricant through the
fittings in order to lubricate the kingpin bearings. 10. Install the top retaining plate and install the
bottom retaining plate.
i02704846
11. Repeat Steps 2 through 10 for the opposite side
Moldboard Wear Strip - of the moldboard.
Inspect/Adjust/Replace Note: Keeping the wear strips adjusted to
specifications regularly will prolong life of
SMCS Code: 6174-025; 6174-040; 6174-510 components.
1. Rotate the blade. Position the blade at an angle
of 90 degrees to the frame. Lower the blade to i02534379
10 mm (0.40 inch) above the ground. Engage the
parking brake. Stop the engine. Oil Filter (All Wheel Drive) -
Replace
SMCS Code: 5068-510-YW

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-
g01298017 ing, adjusting and repair of the product. Be prepared to
Illustration 169
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
2. Visually inspect the wear strips through the cutout nent containing fluids.
feature that is provided on top retaining plate (2)
and bottom retaining plate (3). If the wear strips Refer to Special Publication, NENG2500, “Caterpillar
are worn close to the moldboard, replace the wear Dealer Service Tool Catalog” for tools and supplies
strips. suitable to collect and contain fluids on Caterpillar
products.
3. Remove top retaining plate (2) and bottom
retaining plate (3). Dispose of all fluids according to local regulations and
mandates.
4. Loosen the locknuts on set screws (1).
138 SEBU7881-02
Maintenance Section
Oil Filter (Hydraulic Tank Return) - Replace

5. Clean the filter bases. Check for any pieces of the

seal from the old filters. Remove any pieces of the
seal from the old filters.

6. Apply a thin coat of clean hydraulic oil to the seal

of the new filters.

7. Install the new filters by hand until the seals of the

new filters contact the bases. Note the position of
the index marks on the filters in relation to a fixed
point on the filter mounting bases.

Note: There are rotation index marks on the filters

that are spaced 90 degrees or 1/4 of a turn away
from each other. When you tighten the filters, use the
rotation index marks as a guide.

8. Tighten the filters according to the instructions

that are printed on the filters. Use the index marks
as a guide. For non-Caterpillar filters, use the
instructions that are provided with the filters.
g01263224
Illustration 170
Note: You may need to use a Caterpillar strap
1. Clean the area around hydraulic oil filler cap (1) of wrench, or another suitable tool, in order to turn
any dirt or debris. This must be done before the the filters to the amount that is required for final
hydraulic oil filler cap can be removed. installation. Make sure that the installation tool does
not damage the filters.
2. Slowly remove the hydraulic oil filler cap in order
to relieve the tank pressure. 9. Maintain the hydraulic oil level above the “MIN”
mark in sight gauge (2).

10. Inspect the filler cap gasket. If the filler cap gasket
is damaged, replace the filler cap gasket.

11. Install the hydraulic oil filler cap.

i02534393

Oil Filter (Hydraulic Tank

Return) - Replace
SMCS Code: 5068-510

Hot oil and hot components can cause personal

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

g01263264
Illustration 171

3. Clean the area around filters (3). This must be

done before the filters can be removed.

4. Remove the filters with a strap type wrench. See

Operation and Maintenance Manual, “Oil Filter -
Inspect”. Discard the used filters properly.
SEBU7881-02 139
Maintenance Section
Oil Filter (Implement Controls) - Replace

4. Remove the filter with a strap type wrench. See

NOTICE Operation and Maintenance Manual, “Oil Filter -
Care must be taken to ensure that fluids are contained Inspect”. Discard the used filter properly.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to 5. Clean the filter base. Check for any pieces of the
collect the fluid with suitable containers before open- seal from the old filter. Remove any pieces of the
ing any compartment or disassembling any compo- seal from the old filter.
nent containing fluids.
6. Apply a thin coat of clean hydraulic oil to the seal
Refer to Special Publication, NENG2500, “Caterpillar of the new filter.
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar 7. Install the new filter by hand until the seal of the
products. new filter contacts the base. Note the position of
the index marks on the filter in relation to a fixed
Dispose of all fluids according to local regulations and point on the filter mounting base.
mandates.
Note: There are rotation index marks on the filter
that are spaced 90 degrees or 1/4 of a turn away
Park the machine on a level surface with front wheels from each other. When you tighten the filter, use the
straight ahead. Lower all attachments to the ground. rotation index marks as a guide.
Apply a slight downward pressure to the attachments.
Center the articulation of the machine and install 8. Tighten the filter according to the instructions that
the frame lock pin. The frame lock pin must move are printed on the filter. Use the index marks as a
freely in the frame. Move the front wheels to vertical guide for tightening the filter. For non-Caterpillar
and install the wheel lean locking bolt. Engage the filters, use the instructions that are provided with
parking brake. Stop the engine. the filter.

Note: You may need to use a Caterpillar strap

wrench, or another suitable tool, in order to turn
the filter to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filter.

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

mark in sight gauge (2).

10. Inspect the filler cap gasket. If the filler cap gasket
is damaged, replace the filler cap gasket.

11. Install the hydraulic oil filler cap.

i02534401

Oil Filter (Implement Controls)

- Replace
Illustration 172
g01267806 SMCS Code: 5068-510

1. Clean the area around hydraulic oil filler cap (1) of

any dirt or debris. This must be done before the
hydraulic oil filler cap can be removed. Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
2. Slowly remove the hydraulic oil filler cap in order contact skin.
to relieve the tank pressure.

3. Clean the area around filter (3). This must be done

before the filter can be removed.
140 SEBU7881-02
Maintenance Section
Oil Filter (Implement Controls) - Replace

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

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

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 g01267876
the frame lock pin. The frame lock pin must move Illustration 174
freely in the frame. Move the front wheels to vertical
and install the wheel lean locking bolt. Engage the 3. Clean the area around filter (3). This must be done
parking brake. Stop the engine. before the filter can be removed.

4. Remove the filter with a strap type wrench. See

Operation and Maintenance Manual, “Oil Filter -
Inspect”. Discard the used filter properly.

5. Clean the filter base. Check for any pieces of the

seal from the old filter. Remove any pieces of the
seal from the old filter.

6. Apply a thin coat of clean hydraulic oil to the seal

of the new filter.

7. Install the new filter by hand until the seal of the

new filter contacts the base. Note the position of
the index marks on the filter in relation to a fixed
point on the filter mounting base.

Note: There are rotation index marks on the filter

that are spaced 90 degrees or 1/4 of a turn away
from each other. When you tighten the filter, use the
rotation index marks as a guide.
g01263224
Illustration 173 8. Tighten the filter according to the instructions that
are printed on the filter. Use the index marks as a
1. Clean the area around hydraulic oil filler cap (1) of guide for tightening the filter. For non-Caterpillar
any dirt or debris. This must be done before the filters, use the instructions that are provided with
hydraulic oil filler cap can be removed. the filter.

2. Slowly remove the hydraulic oil filler cap in order Note: You may need to use a Caterpillar strap
to relieve the tank pressure. wrench, or another suitable tool, in order to turn
the filter to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filter.

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

mark in sight gauge (2).
SEBU7881-02 141
Maintenance Section
Oil Filter - Inspect

10. Inspect the filler cap gasket. If the filler cap gasket i02710430
is damaged, replace the filler cap gasket.
Piston Motor (AWD) Oil -
11. Install the hydraulic oil filler cap. Change
i02106227
SMCS Code: 4351-044-OC

Oil Filter - Inspect NOTICE

Care must be taken to ensure that fluids are contained
SMCS Code: 1308-507; 3004-507; 3067-507; during performance of inspection, maintenance, test-
5068-507 ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
Inspect a Used Filter for Debris ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

Note: If the all wheel drive oil is not being monitored

by the Caterpillar S·O·S Services program or an
equivalent oil sampling program, change the all
wheel drive oil at every 2000 service hour interval.
g00100013
Illustration 175
The element is shown with debris.

Hot oil and hot components can cause personal

Use a filter cutter to cut the filter element open.
injury. Do not allow hot oil or hot components to
Spread apart the pleats and inspect the element for
contact skin.
metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
failure. Operate the machine until the oil is warm.

If metals are found in the filter element, a magnet can Park the machine on a level surface with the front
be used to differentiate between ferrous metals and wheel straight ahead. Lower all attachments to the
nonferrous metals. ground. Apply a slight downward pressure to the
attachments. Center the articulation of the machine
Ferrous metals can indicate wear on steel parts and and install the frame lock pin. The frame lock pin
on cast iron parts. must move freely in the frame. Move the front wheels
to vertical and install the wheel lean bolt. Engage the
Nonferrous metals can indicate wear on the parking brake. Stop the engine.
aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings. The all wheel drive system has an oil drain plug and
an oil filler plug on each front wheel. The all wheel
Small amounts of debris may be found in the filter drive oil must be changed on both wheels.
element. This could be caused by friction and by
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount
of debris is found.

Using an oil filter element that is not recommended

by Caterpillar can result in severe engine damage
to engine bearings, to the crankshaft, and to other
parts. This can result in larger particles in unfiltered
oil. The particles could enter the lubricating system
and the particles could cause damage.
142 SEBU7881-02
Maintenance Section
Piston Motor (AWD) Oil Level - Check

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.

Check the all wheel drive oil level by opening the oil
filler plug. The oil filler plug is located on the front
wheel of the machine. There is an oil filler plug on
each front wheel of the machine.

g01360462
Illustration 176

Note: Position the wheel so the oil filler plug (1) is at

the nine o’clock position.

1. Clean the area around the all wheel drive oil filler
plug (1) and the all wheel drive oil drain plug (2).

2. Slowly remove the all wheel drive oil filler plug in

order to relieve the pressure.

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

suitable container.
g01360644
Illustration 177
4. Replace the drain plug and tighten the drain plug.
Clean the area around the drain plug. Note: Position the wheel so the oil filler plug (1) is at
the nine o’clock position.
5. Open the filler plug (1).
1. Clean the area around the all wheel drive oil filler
6. Fill the all wheel drive oil gearbox through the filler plug of any dirt or debris. This must be done before
plug to a level even with the filler plug. the all wheel drive oil filler plug can be removed.

7. Replace the filler plug and tighten the filler plug. 2. Open the oil filler plug (1).

8. Repeat these steps on the other wheel. 3. Maintain the oil level even with the oil filler plug (1).

4. If necessary, add oil through the oil filler plug

i02710843
opening.
Piston Motor (AWD) Oil Level - 5. Clean the oil filler plug and install the oil filler plug.
Check
SMCS Code: 4351-535-FLV i02710878

Piston Motor (AWD) Oil Sample

- Obtain
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to SMCS Code: 4351-008-OC
contact skin.

Operate the machine until the oil is warm.

Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact skin.
SEBU7881-02 143
Maintenance Section
Radiator - Clean

i02535234
NOTICE
Care must be taken to ensure that fluids are contained
Radiator - Clean
during performance of inspection, maintenance, test-
SMCS Code: 1353-070; 1805-070; 1810-070
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

g01268789
Illustration 179

1. Open the access cover on the left rear of the

machine.

2. Remove the bolts that hold the All Wheel Drive

(AWD) cooler and/or the air conditioner condenser
to the radiator.

Note: The bolts are located on the left side of the

engine compartment near the rear of the machine.
g01360715
Illustration 178 3. Swing the AWD cooler and/or the air conditioner
condenser approximately 76 mm (3 inches)
The all wheel drive oil drain plug (1) is located on the toward the front of the machine.
front wheel of the machine.
Note: The hinges that allow the AWD cooler and/or
Refer to Special Publication, SEBU6250, “S·O·S the air conditioner condenser to swing are located on
Services Oil Analysis” for information that pertains the right side of the engine compartment near the
to obtaining a sample of the hydraulic oil. Refer rear of the machine.
to Special Publication, PEHP6001, “How To Take
A Good Oil Sample” for more information about 4. Remove any dirt from the area around the radiator.
obtaining a sample of the hydraulic oil. Remove any debris from the area around the
radiator.

5. Swing the AWD cooler and/or the air conditioner

condenser approximately 76 mm (3 inches)
toward the rear of the machine.

6. Install the bolts in order to secure the AWD

cooler and/or the air conditioner condenser to the
radiator.

7. Close the left access cover.

144 SEBU7881-02
Maintenance Section
Radiator Core - Clean

i01671005

Radiator Core - Clean

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

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.
g01268854
Illustration 180
i02667695

Receiver Dryer (Refrigerant) - In-line refrigerant dryer (1) and refrigerant

accumulator (2) are located behind the cab on the
Replace right side.

SMCS Code: 7322-510 Refer to Service Manual, SENR5664, “Air

Conditioning and Heating with R-134a for All
Caterpillar Machines”, “In-Line Refrigerant Dryer -
Remove and Install” for the replacement procedure
Personal injury can result from contact with refrig- of the in-line refrigerant dryer.
erant.
Refer to Service Manual, SENR5664, “Air
Contact with refrigerant can cause frost bite. Keep Conditioning and Heating with R-134a for All
face and hands away to help prevent injury. Caterpillar Machines”, “Refrigerant Accumulator -
Remove and Install” for the replacement procedure
Protective goggles must always be worn when re- of the refrigerant dryer.
frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant. i02598720

Always use precaution when a fitting is removed. Ripper Cylinder Bearings -

Slowly loosen the fitting. If the system is still un-
der pressure, release it slowly in a well ventilated
Lubricate
area.
SMCS Code: 5352-086; 6325-086
Personal injury or death can result from inhaling
Note: Caterpillar recommends the use of 5%
refrigerant through a lit cigarette.
molybdenum grease for lubricating the ripper cylinder
bearings. Refer to Special Publication, SEBU6250,
Inhaling air conditioner refrigerant gas through a
“Caterpillar Machine Fluids Recommendations” for
lit cigarette or other smoking method or inhaling
more information on molybdenum grease.
fumes released from a flame contacting air con-
ditioner refrigerant gas, can cause bodily harm or
Wipe all the fittings before you apply lubricant through
death.
the fittings.
Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.

Use a certified recovery and recycling cart to prop-

erly remove the refrigerant from the air condition-
ing system.
SEBU7881-02 145
Maintenance Section
Ripper Tip - Inspect/Replace

g01287430 g00110460
Illustration 181 Illustration 182

Fitting (1) is on each side of the trunnion. Apply the 2. Drive out the retainer pin from the retainer side
appropriate lubricant through each fitting in order to of the ripper tip. Remove the ripper tip and the
lubricate the trunnion. retainer.

Fitting (2) is mounted on the left side rod end of 3. Clean the adapter, the retainer pin, and the
the ripper cylinder. Apply the appropriate lubricant retainer. Install the retainer in the groove.
through the fitting in order to lubricate the rod end of
the ripper cylinder. 4. Install the new ripper tip over the retainer.

5. Drive the retainer pin through the retainer, through

i01563909
the adapter, and through the ripper tip from the
Ripper Tip - Inspect/Replace opposite side of the retainer.

SMCS Code: 6808-040; 6808-510 6. Repeat Step 2 through Step 5 in order to replace
additional ripper tips.

7. Raise the ripper. Remove the block. Lower the

ripper to the ground.
Personal injury or death can result from the ripper
falling.
i02538048

Block the ripper before changing teeth.

Rollover Protective Structure
(ROPS) - Inspect
SMCS Code: 7323-040; 7325-040
Retainer pin, when struck with force, can fly out
and cause injury to nearby people. NOTICE
Do not attempt to straighten the ROPS structure. Do
Make sure the area is clear of people when driving not repair the ROPS by welding reinforcement plates
retainer pins. to the structure.
To avoid injury to your eyes, wear protective If there are any cracks in the welds, in the castings, or
glasses when striking a retainer pin. in any metal section of the ROPS, consult your Cater-
pillar dealer for repairs.
Inspect the ripper tips. Replace the ripper tips if the
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.
146 SEBU7881-02
Maintenance Section
Scarifier Lift Link Socket - Lubricate

g01270477 g01073062
Illustration 183 Illustration 184

1. There are four mounting bolts (1) for the ROPS. The machine has two fittings on each side. Apply the
Two mounting bolts are located on each side of appropriate lubricant through the fittings in order to
the cab. lubricate the scarifier lift link socket.

2. Inspect the ROPS for any loose bolts or any

i02589744
damaged bolts. Replace any damaged mounting
bolts or any missing mounting bolts with only
original equipment parts.
Scarifier Teeth -
Inspect/Replace
3. If necessary, tighten the four mounting bolts.
Refer to Specifications, SENR3130, “Torque SMCS Code: 6807-040; 6807-510
Specifications” for the recommended torque.

4. When you operate the machine on a rough

surface, the ROPS may rattle or the ROPS may Personal injury or death can result from the scar-
make a noise. If the ROPS rattles or if the ROPS ifier falling.
makes a noise, replace the ROPS mounting
supports. Block the scarifier before changing the teeth.

i02588674

Scarifier Lift Link Socket -

Flying objects can cause injury or death.
Lubricate
(If Equipped) Make sure the area is clear of people when remov-
ing/installing scarifier teeth.
SMCS Code: 6162-086-LNK
To avoid injury to your eyes, wear protective
Note: Caterpillar recommends the use of 5% glasses when removing/installing scarifier teeth.
molybdenum grease for lubricating the scarifier lift
link socket. Refer to Special Publication, SEBU6250,
If the scarifier teeth are damaged or worn excessively,
“Caterpillar Machine Fluids Recommendations” for
then change the scarifier teeth.
more information on molybdenum grease.

Wipe the fittings before you apply lubricant through

the fittings.
SEBU7881-02 147
Maintenance Section
Scarifier Teeth - Inspect/Replace

If the scarifier teeth are damaged or worn excessively,

then change the scarifier teeth.

g01296557
Illustration 185

1. Block up the scarifier. Do not block up the scarifier Illustration 186

g01073079
too high. Block up the scarifier to a height that
allows you to remove the teeth. 1. Block up the scarifier. Do not block up the scarifier
too high. Block up the scarifier to a height that
2. Remove the scarifier tooth from the shank. allows you to remove the teeth.

3. Clean the shank. 2. Remove the scarifier tooth from the shank.

4. Install the new scarifier tooth over the shank. 3. Clean the shank.

5. Drive the scarifier tooth onto the shank. 4. Install the new scarifier tooth over the shank.

6. Repeat Step 2 through Step 5 in order to replace 5. Drive the scarifier tooth onto the shank.
additional scarifier teeth.
6. Repeat Step 2 through Step 5 in order to replace
7. Raise the scarifier and remove blocking. additional scarifier teeth.

7. Raise the scarifier and remove blocking.

i02588690

Scarifier Teeth - i02429589

Inspect/Replace Seat Belt - Inspect
(If Equipped)
SMCS Code: 7327-040
SMCS Code: 6807-040; 6807-510
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.
Personal injury or death can result from the scar-
ifier falling.

Block the scarifier before changing the teeth.

Flying objects can cause injury or death.

Make sure the area is clear of people when remov-

ing/installing scarifier teeth.

To avoid injury to your eyes, wear protective

glasses when removing/installing scarifier teeth.
148 SEBU7881-02
Maintenance Section
Seat Belt - Replace

g01152685
Illustration 188

Illustration 187
g00932801 (1) Date of installation (retractor)
(2) Date of installation (buckle)
Typical example (3) Date of manufacture (tag) (fully extended web)
(4) Date of manufacture (underside) (buckle)
Check the seat belt mounting hardware (1) for wear
or for damage. Replace any mounting hardware that Consult your Caterpillar dealer for the replacement of
is worn or damaged. Make sure that the mounting the seat belt and the mounting hardware.
bolts are tight.
If your machine is equipped with a seat belt
Check buckle (2) for wear or for damage. If the buckle extension, also perform this replacement procedure
is worn or damaged, replace the seat belt. for the seat belt extension.

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

i02538155
frayed. Replace the seat belt if the seat belt is worn
or frayed. Steering Cylinder Ends and Tie
Consult your Caterpillar dealer for the replacement of Rods - Lubricate
the seat belt and the mounting hardware.
SMCS Code: 4303-086-BD; 4318-086
Note: Within three years of the date of installation or
within five years of the date of manufacture, replace Note: Caterpillar recommends the use of
the seat belt. Replace the seat belt at the date which 5% molybdenum grease for lubricating the
occurs first. A date label for determining the age of cylinder ends and the tie rods. Refer to Special
the seat belt is attached to the seat belt, the seat belt Publication, SEBU6250, “Caterpillar Machine
buckle, and the seat belt retractor. Fluids Recommendations” for more information on
molybdenum grease.
If your machine is equipped with a seat belt
extension, also perform this inspection procedure for Wipe the fittings before you apply lubricant through
the seat belt extension. the fittings.

i02429594

Seat Belt - Replace

SMCS Code: 7327-510

Within three years of the date of installation or within

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

g01142294
Illustration 189
SEBU7881-02 149
Maintenance Section
Tandem Breather - Clean/Replace

Both steering cylinders have two fittings. Both tie i02593825

rods have one fitting. Apply the appropriate lubricant
through the fittings in order to lubricate the cylinder Tandem Drive Oil - Change
ends and the tie rods.
SMCS Code: 4071-510

i02593781

Tandem Breather -
Hot oil and hot components can cause personal
Clean/Replace injury. Do not allow hot oil or hot components to
contact skin.
SMCS Code: 4062-070-BRE; 4062-510-BRE

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

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

g01298118
Illustration 190 mandates.
The tandem breathers are located on the top of each tandem.

1. Remove a plate from the walkway that is located

on top of the tandem drive housings. This must be
done in order to access breathers (1) on the top of
the tandem drive housings.

2. Clean the area around the breathers of any dirt or

debris. This must be done before the breathers
are removed.

3. Remove breather (1) from both tandems.

4. Wash the breathers in clean, nonflammable

solvent.
g01298140
Illustration 191
5. Use pressure air to dry the breathers.
1. Clean the surface area around oil check plug (1).
6. Install the breathers in both tandems.
2. Remove drain plug (2). Remove the oil check plug.
Note: Replace the breathers if the breathers are Allow the oil to drain into a suitable container.
damaged.
Note: When you change the tandem drive oil, use
7. Install the plate to the walkway. diesel fuel in order to clean the housing of the sludge
and flush the housing of the sludge.

3. Clean the drain plug and install the drain plug.

4. Remove a plate from the walkway that is located

on top of the tandem drive housing. This must be
done in order to access one of the covers on the
top of the tandem drive housing.
150 SEBU7881-02
Maintenance Section
Tandem Drive Oil Level - Check

5. Clean the area around one of the covers of any 2. Remove the oil check plug.
dirt or debris. This must be done before the cover
is removed. 3. Maintain the oil level to the bottom of the opening
for the oil check plug. If additional oil is necessary,
6. Remove a cover from the top of the tandem drive perform the following Steps:
housing. Fill the tandem drive housing with new
oil. Refer to the following topics: a. Remove a plate from the walkway that is
located on top of the tandem drive housing.
• Operation and Maintenance Manual, “Lubricant This must be done in order to access one of the
Viscosities” covers on the top of the tandem drive housing.

• Operation and Maintenance Manual, “Capacities b. Clean the area around one of the covers of
(Refill)” any dirt or debris. This must be done before
the cover is removed.
7. Clean the cover and install the cover on the top of
the tandem drive housing. c. Remove a cover from the top of the tandem
drive housing. Fill the tandem drive housing
8. Install the plate to the walkway. with new oil. Refer to the following topics:

9. Clean the oil check plug and install the oil check • Operation and Maintenance Manual,
plug. “Lubricant Viscosities”

10. Start the engine. Operate the machine for a few • Operation and Maintenance Manual,
minutes. Check the tandem drive housing for “Capacities (Refill)”
leaks.
d. Clean the cover and install the cover on the top
11. Stop the engine. Remove the oil check plug. of the tandem drive housing.

12. Check the oil level. Maintain the oil level to the e. Install the plate to the walkway.
bottom of the opening for the oil check plug. Add
oil, if necessary. 4. Clean the oil check plug and install the oil check
plug.
13. Install the oil check plug.
i02594019
14. Repeat Step 1 through Step 13 for the other side
of the machine. Tandem Drive Oil Sample -
i02593951
Obtain
Tandem Drive Oil Level - Check SMCS Code: 4071-008

SMCS Code: 4071-535

g01298256
Illustration 193

Illustration 192
g01298219 1. Remove a plate from the walkway that is located
on top of the tandem drive housing. This must be
1. Clean the surface area around the oil check plug. done in order to access one of the covers on the
top of the tandem drive housing.
SEBU7881-02 151
Maintenance Section
Tire Inflation - Check

2. Clean the area around one of the covers of any i02663100

dirt or debris. This must be done before the cover
is removed. Transmission and Differential
3. Remove a cover from the top of the tandem drive
Oil - Change
housing in order to obtain an oil sample. SMCS Code: 3080-510; 3258-510-OC
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations”, “S·O·S Services
Oil Analysis” for information that pertains to obtaining
a sample of the tandem drive oil. Refer to Special Hot oil and hot components can cause personal
Publication, PEHP6001, “How To Take A Good Oil injury. Do not allow hot oil or hot components to
Sample” for more information about obtaining a contact skin.
sample of the tandem drive oil.
NOTICE
i00149440 Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
Tire Inflation - Check ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
SMCS Code: 4203-535-AI; 4203-535-PX ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

Refer to Operation and Maintenance Manual,

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

Illustration 194
g00103147 Clean the area around the differential drain plug and
the area around the transmission drain plug. Refer
Measure the air pressure on each tire. Consult your to Illustration 195 for the location of drain plugs.
tire dealer for the correct load rating and for the Clean the area around the oil level gauge/fill cap.
correct operating pressures. Refer to Illustration 196 for the location of the oil level
gauge/fill cap.
If necessary, inflate the tires. Refer to the following
additional information about tire inflation: Operate the engine until the transmission oil and the
differential oil are 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 case and drain the
differential case while the oil is warm. This allows
• Operation and Maintenance Manual, “Tire Inflation waste particles that are suspended in the oil to drain.
Pressure Adjustment” As the oil cools, the 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 system with the new oil.
152 SEBU7881-02
Maintenance Section
Transmission and Differential Oil Filter and Screens - Replace/Clean

• Operation and Maintenance Manual, “Capacities

(Refill)”

6. Remove transmission breather (4) and discard the

transmission breather. Install a new transmission
breather.

7. Start the engine and run the engine at low

idle. Inspect the transmission and differential
components for leaks.

8. Engage the transmission modulator control

(inching pedal). Slowly operate the transmission
in order to circulate the oil.

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

between the marks on the oil level gauge. If
necessary, add oil through oil level gauge/fill cap
(3).

10. Stop the engine.

g01271184
Illustration 195
Bottom view
11. Close the access door.

1. Remove transmission drain plug (1) and remove i02584516

differential drain plug (2). Drain the oil into a
suitable container. Transmission and Differential
2. Change the filter element and clean the screens.
Oil Filter and Screens -
Refer to Operation and Maintenance Manual, Replace/Clean
“Transmission and Differential Oil Filter and
Screens - Replace/Clean” for the proper SMCS Code: 3030-070-Z3; 3030-510-Z3;
procedure. 3067-070; 3067-510; 3258-070-FI; 3258-070-Z3;
3258-510-Z3; 3258-510-FI
3. Clean the drain plugs and install the drain plugs.

4. Open the front left access door.

Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact skin.

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

Refer to Special Publication, NENG2500, “Caterpillar

g01294176 Dealer Service Tool Catalog” for tools and supplies
Illustration 196
suitable to collect and contain fluids on Caterpillar
products.
5. Fill the transmission case and the differential case
with oil through oil level gauge/fill cap (3). Refer Dispose of all fluids according to local regulations and
to the following topics: mandates.
• Operation and Maintenance Manual, “Lubricant
Viscosities”
SEBU7881-02 153
Maintenance Section
Transmission and Differential Oil Filter and Screens - Replace/Clean

8. Replace the filter housing base seal.

9. Install the transmission oil filter housing.

10. Install drain plug (4) in transmission oil filter

housing (3).

g01271450
Illustration 197
g01271420 Illustration 199

Cutaway view
11. Slowly remove the cover for magnetic screen
(6). Slowly remove the cover for supplemental
magnetic screen (5). Allow the oil to drain into a
suitable container.

12. Remove the magnetic screen tube assemblies.

13. 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-
g01271423
Illustration 198 age can result. Replace damaged magnets.

1. Remove drain plug (4) on transmission oil filter

housing (3). Allow the oil to drain into a suitable 14. Clean the magnets with a cloth or clean the
container. magnets with a firm brush. Allow the magnets to
dry.
2. Loosen oil sampling valve (1) or pressure test
port (2) in order to vent the transmission oil filter 15. Install the magnets and the tube assemblies into
housing. the screens.

3. Remove the transmission oil filter housing. 16. Install the screens.

4. Remove the used element and discard the used 17. Inspect the cover seals. If the cover seals are
element. damaged, replace the cover seals.

5. Clean the transmission oil filter housing with a 18. Install the covers and tighten the bolts.
clean, nonflammable solvent.
19. Start the engine.
6. Clean the base of the transmission oil filter
housing. 20. With the parking brake engaged, run the engine
at low idle in order to circulate the transmission oil.
7. Insert a new filter element into the transmission oil
filter housing. 21. Inspect all of the transmission components for
leaks.
154 SEBU7881-02
Maintenance Section
Transmission and Differential Oil Level - Check

1. Open the front left access door.

2. Clean the area around oil level gauge/fill cap (1).

3. Start the engine and run the engine at low idle.

Remove the oil level gauge/fill cap.

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

between the marks on oil level gauge/fill cap (1). If
necessary, add oil.

5. Stop the engine.

6. Close the access door.

g01294173
Illustration 200
i02540233
22. Clean the area around oil level gauge/fill cap (7).
Transmission and Differential
23. With the engine at low idle, maintain the oil level Oil Sample - Obtain
between the marks on the oil level gauge. If
necessary, add oil through oil level gauge/fill cap SMCS Code: 3006-008; 3030-008; 3080-008;
(7). 3258-008; 7542
24. Stop the engine.

i02584502 Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
Transmission and Differential contact skin.
Oil Level - Check
SMCS Code: 3030-535-FLV; 3080-535-FLV; NOTICE
3258-535-FLV 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-
Hot oil and hot components can cause personal nent containing fluids.
injury. Do not allow hot oil or hot components to
contact skin. Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
Refer to Operation and Maintenance Manual, suitable to collect and contain fluids on Caterpillar
“Access Doors and Covers” for the location of the products.
service points.
Dispose of all fluids according to local regulations and
mandates.

g01294168
Illustration 201
SEBU7881-02 155
Maintenance Section
Wheel Bearing Oil (Front) - 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

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

g01271753
Illustration 202

Sampling valve (1) for the transmission and

differential oil is located on the transmission filter.
The transmission filter is located on the right, rear
of the transmission.

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

Services Oil Analysis” for information that pertains to
obtaining a sample of the transmission and differential
oil. Refer to Special Publication, PEHP6001, “How g01271804
Illustration 203
To Take A Good Oil Sample” for more information The wheel has been removed for ease of viewing.
about obtaining a sample of the transmission and
differential oil. The front wheel bearings are located on the inner
side of each front wheel. Check/fill plug (1) is located
i02517674
on the housings of each front wheel bearing.

Wheel Bearing Oil (Front) - 1. Clean the surface around the check/fill plug.
Change 2. Remove the check/fill plug.
SMCS Code: 4205-044; 4208-044; 4234-044; 3. Use a 1U-7683 Suction Gun in order to remove
7551-044-WHL the oil from the housing for the wheel bearing.

4. Add oil to the housing for the wheel bearing until

the oil level is at the bottom of the opening for the
Hot oil and hot components can cause personal check/fill plug. Refer to the following topics:
injury. Do not allow hot oil or hot components to
contact skin. • Operation and Maintenance Manual, “Lubricant
Viscosities”

• Operation and Maintenance Manual, “Capacities

(Refill)”

5. Install the check/fill plug.

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

bearing.
156 SEBU7881-02
Maintenance Section
Wheel Bearing Oil Level (Front) - Check

i02540480

Wheel Bearing Oil Level (Front)

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

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact skin.
g01271900
Illustration 205
The wheel has been removed for ease of viewing.

Each front wheel has one fitting. Apply the

appropriate lubricant through the fittings in order to
lubricate the wheel lean bar bearings.

i02540560

Wheel Lean Bearings -

Lubricate
SMCS Code: 5225-086-BD
g01271804
Illustration 204
Note: Caterpillar recommends the use of 5%
The wheel has been removed for ease of viewing.
molybdenum grease for lubricating the wheel lean
bearings. Refer to Special Publication, SEBU6250,
1. Clean the surface around check/fill plug (1).
“Caterpillar Machine Fluids Recommendations” for
more information on molybdenum grease.
2. Remove the check/fill plug.
Wipe the fittings before you apply lubricant through
3. Maintain the oil level to the bottom of the opening
the fittings.
for the check/fill plug. If necessary, add oil.

4. Install the check/fill plug.

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

bearing.

i02622524

Wheel Lean Bar Bearings -

Lubricate
SMCS Code: 5225-086-BD

Note: Caterpillar recommends the use of 5% g01271922

Illustration 206
molybdenum grease for lubricating the wheel lean bar
bearings. Refer to Special Publication, SEBU6250, The wheel has been removed for ease of viewing.
“Caterpillar Machine Fluids Recommendations” for
more information on molybdenum grease. Each front wheel has two fittings. Apply the
appropriate lubricant through the fittings in order to
Wipe the fittings before you apply lubricant through lubricate the wheel lean bearings.
the fittings.
SEBU7881-02 157
Maintenance Section
Wheel Lean Cylinder Bearings - Lubricate

i02540570

Wheel Lean Cylinder Bearings

- Lubricate
SMCS Code: 5211-086-BD

Note: Caterpillar recommends the use of

5% molybdenum grease for lubricating the
wheel lean cylinder bearings. Refer to Special
Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” for more information on
molybdenum grease.

Wipe the fittings before you apply lubricant through Illustration 208
g01323517
the fittings.
1. Clean the filler cap and the surrounding area.

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.

Note: The window washer nozzles can be adjusted

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

g01271952
Illustration 207 i02583044
The wheel has been removed for ease of viewing.
Window Wiper -
The right front wheel has two fittings on the wheel Inspect/Replace
lean cylinder. Apply the appropriate lubricant through
the fittings in order to lubricate the wheel lean cylinder SMCS Code: 7305-040; 7305-510
bearings.

i02639345

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.
g01293778
Illustration 209

The windshield washer reservoir is positioned in Inspect front windshield wiper blade (1). Inspect left
the seat support to the left of the operator’s seat. windshield wiper blade (2). If equipped, inspect the
The level of windshield washer fluid can be viewed right windshield wiper blade and the rear window
through the reservoir. wiper blade. If any of the wiper blades are streaking
any of the windshields or the rear window, replace
the wiper blade.
158 SEBU7881-02
Maintenance Section
Windows - Clean

i02597717 Wipe the fittings before you apply lubricant through

the fittings.
Windows - Clean
SMCS Code: 7310-070; 7340-070

When cleaning the windows, use the recommend-

ed procedure in this manual. Serious injury or
death could result from falling if the appropriate
procedure and equipment is not used.

g01296618
Illustration 211

The machine has eleven fittings. Apply the

appropriate lubricant through the fittings in order to
lubricate the work tool lift.

g01293786
Illustration 210

Clean the front, left side, and right side windows of

the cab while you are standing on the ground or on a
stable work platform. Use the appropriate equipment
in order to reach the windows. If you are standing
on the ground, use a squeegee with an extension
handle.

Clean the rear window from the top of the left tandem
housing. Access this area by using the step that is
located at the rear of the tandem housing. Be sure to
use the area of the walkway that is covered with a
slip resistant surface. Use the provided handholds on
the engine enclosure to maintain a secure position. If
necessary, use a squeegee with an extension handle
to fully reach across the rear window.

Use commercially available window cleaning

solutions to clean the windows.

i02589851

Work Tool Lift - Lubricate

SMCS Code: 6700-086

Note: Caterpillar recommends the use of 5%

molybdenum grease for lubricating the work tool lift.
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” for more
information on molybdenum grease.
SEBU7881-02 159
Reference Information Section
Reference Materials

Reference Information Special Instruction, SEHS9187, “Brake Linings

Require Conditioning On Machines With Drum
Section Brakes”

Special Instruction, SMHS7867, “6V-4040 Nitrogen

Tire Inflation Group”
Reference Materials
Special Publication, NENG2500, “Caterpillar Dealer
Service Tool Catalog”
i02578579

Reference Material Special Publication, PEHP6001, “How to Take a

Good Oil Sample”
SMCS Code: 1000; 7000
Special Publication, PEHP7057, “S·O·S Coolant
Analysis”
Caterpillar Reference Material
Special Publication, PEHP7076, “Understanding
The following literature can be obtained from any S·O·S Services Test”
Caterpillar dealer:
Special Publication, PEWJ0074, “Caterpillar Filter
Special Publication, PEDP7035, “Optimizing Oil and Fluid Application Guide”
Change Intervals”
Special Publication, PMEP5027, “Extended Life
Special Publication, PEDP7036, “S·O·S Fluid Coolant/Antifreeze Label”
Analysis”
Special Publication, SEBD0400, “Dictionary of
Operation and Maintenance Manual, SEBU8257, Pictograph Symbols”
“The European Union Physical Agents (Vibration)
Directive 2002/44/EC” Special Publication, SEBD0518, “Know Your Cooling
System”
Service Manual, RENR5885, “Product Link 151/201”
Special Publication, SEBD0640, “Oil and Your
Service Manual, SENR5664, “Air Conditioning and Engine”
Heating R-134a for All Caterpillar Machines”
Special Publication, SEBD0717, “Diesel Fuels and
Service Parts, PECP9067, “One Safe Source” Your Engine”
Special Instruction, REHS0354, “Charging System Special Publication, SEBD0970, “Coolant and Your
Troubleshooting” Engine”
Special Instruction, REHS1590, “Installation of Special Publication, SEBD1587, “What ROPS/FOPS
the Machine Security System (MSS) Universal Certification Means”
Attachment Kit”
Special Publication, SEBU5379, “Motor Grader
Special Instruction, REHS1642, “Operation of the Safety Manual - AEM Form G-40-2”
Product Link System”
Special Publication, SEBU5898, “Cold Weather
Special Instruction, RMHS1002, “Operation of the Recommendations for All Caterpillar Machines”
Machine Security System (MSS)”
Special Publication, SEBU6250, “Caterpillar Machine
Special Instruction, SEHS6929, “Inspection, Fluids Recommendations”
Maintenance and Repair of ROPS and Attachment
Installation Guidelines” Special Publication, SMBU6981, “Emissions Control
Warranty Information for US, Canada, and California”
Special Instruction, SEHS7332, “Warning Tag -
Danger Do Not Operate” Specifications, SENR3130, “Torque Specifications”
Special Instruction, SEHS7633, “Battery Test Systems Operation, Testing and Adjusting,
Procedure” Disassembly and Assembly, RENR2165, “Comfort
Series Seat for Caterpillar Machines”
Special Instruction, SEHS9031, “Storage Procedure
for Caterpillar Products”
160 SEBU7881-02
Reference Information Section
Reference Materials

Video Tape, TEVN3926, “Motor Grader Operating i01631981

Techniques - Governmental Application”
Decommissioning and
Video Tape, TEVN3927, “Motor Grader Operating
Techniques - Contractor Application”
Disposal
SMCS Code: 1000; 7000
Service Manual, RENR9010, “Specifications,
Systems Operation, Testing and Adjusting, When the machine is removed from service, local
Schematics” regulations will vary. Disposal of the machine will vary
with local regulations. Consult the nearest Caterpillar
Parts Manual, SEBP4304, “140M Motor Grader dealer for additional information.
B9M1-UP”

Parts Manual, SEBP4976, “140M Motor Grader

B9D1-UP”

Specifications, Systems Operation, Troubleshooting,

Testing and Adjusting, RENR8472, “Motor Grader
Secondary Steering System”

Systems Operation, Troubleshooting, Testing and

Adjusting, RENR9034, “120M-16M Motor Grader
Monitoring System”

Service Manual, RENR9034, “Motor Grader

Monitoring System”

Operation and Maintenance Manuals are available

in other languages. Consult your Caterpillar dealer
for information about obtaining these Operation and
Maintenance Manuals.

Additional Reference Material

ASTM D2896, “TBN Measurements” This can
normally be obtained from your local technological
society, from your local library, or from your local
college.

SAE J313, “Diesel Fuels” This can be found in the

SAE handbook. Also, this publication can be obtained
from your local technological society, from your local
library, or from your local college.

SAE J754, “Nomenclature” This can normally be

found in the SAE handbook.

SAE J183, “Classification” This can normally be

found in the SAE handbook.

Engine Manufacturers Association, “Engine Fluids

Data Book”

Engine Manufacturers Association

Two North LaSalle Street, Suite 2200
Chicago, IL USA 60602
E-mail: [email protected]
(312) 827-8700
Facsimile: (312) 827-8737