Sebu6907-09 M - 24H

MAINTENANCE INTERVALS
Operation and Maintenance

Manual Excerpt
2010 Caterpillar
All Rights Reserved
SEBU6907-09
April 2007
Operation and
Maintenance
Manual
24H Motor Grader
7KK1-Up (Machine)
SEBU6907-09
79
Maintenance Section
Maintenance Interval Schedule
i02755067

SMCS Code: 1000; 7000
Ensure that all safety information, warnings, and
instructions are read and understood before any
operation or any maintenance procedures are
performed.
The user is responsible for the performance of
maintenance, including all adjustments, the use of
proper lubricants, fluids, filters, and the replacement
of components due to normal wear and aging. Failure
to adhere to proper maintenance intervals and
procedures may result in diminished performance of
the product and/or accelerated wear of components.
Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST,
in order to determine the maintenance intervals.
Products that operate in severe operating conditions
may require more frequent maintenance.
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be
performed.
When Required
Automatic Lubrication Reservoir - Fill ................... 81
Battery - Recycle .................................................. 83
Blade Lift Cylinder Socket - Check/Adjust/
Replace ............................................................... 85
Brake Accumulator - Check .................................. 87
Centershift Cylinder Socket - Check/Adjust/
Replace ............................................................... 92
Circle Clearances - Check/Adjust ......................... 93
Circle Drive Oil Level - Check ............................... 97
Circuit Breakers - Reset ........................................ 99
Cutting Edges and End Bits - Inspect/Replace ... 105
Drawbar Ball and Socket End Play Check/Adjust ..................................................... 107
Engine Air Filter Primary Element - Clean/
Replace ............................................................. 108
Engine Air Filter Secondary Element - Replace .. 110
Engine Overheating ............................................. 116
Engine Power Loss .............................................. 116
Ether Starting Aid Cylinder - Replace .................. 117
Evaporator Coil and Heater Coil - Clean ............. 118
Fuel System - Fill ................................................. 119
Fuel System - Prime ........................................... 120
Fuses - Replace .................................................. 124
Moldboard Wear Strip - Inspect/Adjust/Replace .. 131
Oil Filter - Inspect ................................................ 132
Radiator Core - Clean ......................................... 133
Ripper Tip - Inspect/Replace .............................. 134
Steering Accumulator - Check ............................ 136
Window Washer Reservoir - Fill .......................... 148
Window Wiper - Inspect/Replace ........................ 148
Windows - Clean ................................................. 148
Every 10 Service Hours or Daily

Backup Alarm - Test .............................................. 82
Brakes, Indicators and Gauges - Test ................... 89
Circle Drive Pinion Teeth - Lubricate .................... 98
Circle Top - Lubricate ............................................ 98
Cooling System Level - Check ............................ 102
Cooling System Pressure Cap - Clean/Replace .. 103
Engine Air Filter Service Indicator - Inspect ......... 110
Engine Air Precleaner - Clean ............................. 112
Engine Oil Level - Check ..................................... 113
Fuel Tank Water and Sediment - Drain ............... 124
Hydraulic System Oil Level - Check ................... 128
Seat Belt - Inspect .............................................. 135
Every 50 Service Hours or Weekly

Articulation Bearings - Lubricate ........................... 81
Axle Oscillation Bearings - Lubricate .................... 82
Cab Air Filter - Clean/Replace .............................. 91
Crankshaft Vibration Damper - Clean ................. 104
Drawbar Ball and Socket - Lubricate .................. 106
Kingpin Bearings - Lubricate ............................... 129
Ripper Linkage and Cylinder Bearings Lubricate ........................................................... 134
Steering Cylinder Ends - Lubricate ..................... 136
Steering Linkage - Lubricate ............................... 137
Tire Inflation - Check ........................................... 140
Wheel Lean Bar Bearings - Lubricate ................. 146
Wheel Lean Bearings - Lubricate ....................... 146
Wheel Lean Cylinder Bearings - Lubricate ......... 147
Initial 250 Service Hours

Drawbar Ball and Socket End Play Check/Adjust ..................................................... 107
Every 250 Service Hours

Engine Oil Sample - Obtain ................................. 114
Every 250 Service Hours or Monthly

Articulation Cylinder Bearings - Lubricate ............. 81
Battery or Battery Cable - Inspect/Replace .......... 83
Belts - Inspect/Adjust/Replace .............................. 84
Blade Lift Cylinder Socket - Lubricate ................... 86
Blade Tip Pin - Lubricate ....................................... 87
Braking System - Test ........................................... 90
Centershift Cylinder Socket - Lubricate ................ 93
Engine Air Filter Service Indicator Inspect/Replace ................................................. 111
Engine Air Filter Service Indicator Screen Check/Replace ................................................... 112
Engine Oil and Filter - Change ............................ 114
Fan Drive Bearing and Belt Tightener Lubricate ............................................................ 118
Machine Structure - Inspect ................................ 130
Radiator - Clean .................................................. 133
Tandem Drive Oil Level - Check ......................... 139
Transmission and Differential Oil Level - Check .. 144
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Maintenance Section
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Every 6000 Service Hours or 6 Years
Hydraulic System Oil Sample - Obtain ............... 129

Tandem Drive Oil Sample - Obtain ..................... 140
Transmission and Differential Oil Sample Obtain ............................................................... 145
Final Drive Lip Seal - Replace ............................. 119
Every 500 Service Hours or 3 Months

Brake Oil Filter - Replace ...................................... 88
Brake Oil Screen - Clean/Replace ........................ 88
Differential Oil Filter - Replace ............................ 106
Engine Crankcase Breather - Clean .................... 113
Fuel System Water Separator Element Replace ............................................................. 121
Fuel System Secondary Filter - Replace ............ 122
Fuel Tank Cap and Strainer - Clean ................... 123
Hydraulic System Oil Filter - Replace ................. 127
Tandem Breather - Clean/Replace ..................... 138
Transmission and Differential Oil Filter and Screens Replace/Clean .................................................. 142
Wheel Bearing Oil Level (Front) - Check ............ 146
Every 1000 Service Hours or 6 Months

Battery Electrolyte Level - Check .......................... 83
Rollover Protective Structure (ROPS) - Inspect .. 135
Transmission and Differential Oil - Change ........ 140
Every 2000 Service Hours or 1 Year

Blade Cushion Accumulator - Check .................... 85
Circle Drive Oil - Change ...................................... 97
Condenser (Refrigerant) - Clean .......................... 99
Differential Thrust Pin Clearance - Check .......... 106
Engine Valve Lash - Check .................................. 117
Engine Valve Rotators - Inspect .......................... 117
Refrigerant Dryer - Replace ................................ 133
Tandem Drive Oil - Change ................................ 138

Wheel Bearing Oil (Front) - Change ................... 145

Cooling System Water Temperature Regulator Replace ............................................................. 103
Crankshaft Vibration Damper - Inspect ............... 104
Every 3 Years After Date of Installation or

Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 136

Hydraulic System Oil - Change ........................... 126

Cooling System Coolant Extender (ELC) - Add .. 101
Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 100
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81
Maintenance Section
Articulation Bearings - Lubricate
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Articulation Bearings Lubricate
Apply lubricant through fitting (2) in order to

lubricate the cylinder bearing (head end) of the right
articulation cylinder.
Apply lubricant through fitting (1) in order to lubricate
the cylinder bearing (head end) of the left articulation
cylinder.
SMCS Code: 7057-086-BD

Wipe all the fittings before you apply lubricant through
the fittings.
Illustration 103
Illustration 101
g00696238
The upper articulation bearing has one fitting. Apply

lubricant through fitting (1) in order to lubricate the
upper articulation bearing.
The lower articulation bearing has one fitting. Apply
lubricant through fitting (2) in order to lubricate the
lower articulation bearing.
g00720605
The lubrication fittings for the rod end of the

articulation cylinders are located above the
articulation cylinder on the left side of the machine .
the cylinder bearing (rod end) of the right articulation
cylinder.
the cylinder bearing (rod end) of the left articulation
cylinder.
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Articulation Cylinder Bearings

- Lubricate
Wipe all the fittings before you apply lubricant through
the fittings.
Illustration 102
g00720696
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Automatic Lubrication
Reservoir - Fill
SMCS Code: 7540-544-TNK
The automatic lubrication reservoir is located on the
drawbar assembly in front of the circle drive.
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Maintenance Section
Axle Oscillation Bearings - Lubricate
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i01354967
Axle Oscillation Bearings Lubricate

SMCS Code: 3268; 4313
The automatic lubrication system provides lubrication
for the axle oscillation bearings. If a remote line
becomes damaged, install a fitting in place of the
remote line and lubricate the axle oscillation bearing
at the fitting until the line can be replaced.
Illustration 104
g00711749
(1) Cover
(2) Vent plug
(3) Drain plug
Note: Make sure that any pressure in the lubrication

system is released before you loosen any fitting,
any hose, or any component. Make sure that vent
plug (2) is removed before the lubrication reservoir is
filled. If vent plug (2) is not removed, pressure inside
the reservoir will cause the seal on cover (1) to fail
when the reservoir is filled.
Remove vent plug (2) and drain plug (3) in order to
fill the lubricant tank. Use 7H-1680 Lubrication Hand
Pump to fill the lubricant tank. Fill the lubricant tank
through the drain port. Use a suitable container to
collect any lubricant that is spilled.
When the tank is empty, the tank holds 27 kg (60 lb)
of lubricant.
The automatic lubrication reservoir provides
lubrication for many components. There are 18
fittings on the right front side of the machine. There
are 18 fittings on the left front side of the machine.
There are 3 fittings on the left side of the drawbar.
There are 10 fittings on the ripper. There are 2 fittings
on the front frame above the articulation cylinder.
Illustration 105
g00715256
The fittings for the axle oscillation bearings are on the right side
of the machine.
Lubricate fitting (1) in order to lubricate the front axle

oscillation bearing. Lubricate fitting (2) in order to
lubricate the rear axle oscillation bearing.
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Backup Alarm - Test

SMCS Code: 7406-081
Turn the engine start switch to the ON position in
order to perform the test.
If any of the remote lines become damaged, install a

fitting in place of the remote line. Lubricate the item
at the fittings until the remote line can be replaced.
Apply the service brake. Move the transmission

control (lever) to the REVERSE position.
See Service Manual, SENR4724, Automatic

Lubrication System for additional details.
The backup alarm should sound immediately.

The backup alarm should continue to sound until
the transmission control (lever) is moved to the
NEUTRAL position or to any FORWARD position.
There are also two fittings for the fan bearing and for
the adjusting pulley. These components are not part
of the Automatic Lubrication System.
The backup alarm is located at the rear of the

machine.
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Maintenance Section
Battery - Recycle
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Maintain the level of the distilled water to the
bottom of the filler openings. If distilled water is

not available, use clean drinking water.
Battery - Recycle
SMCS Code: 1401-561
A battery should not require more than 30 cc
Always recycle a battery. Never discard a battery.

Always return used batteries to one of the following
locations:
(1 ounce) of water per cell per week. This

requirement should exist with the proper
charging rate and with a moderate climate.
In extreme temperatures, check the water in the

cells weekly. Cell water usage could be higher
in extreme temperatures.
A battery supplier
An authorized battery collection facility
6. Close the battery access cover.
Recycling facility
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i01691202
Battery Electrolyte Level Check

SMCS Code: 1401-535-FLV
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.
Table 6
The Chart for the Battery Electrolyte

Battery
Battery or Battery Cable Inspect/Replace
Interval
Conventional
100 Hour
Low Maintenance
250 Hours
Maintenance Free
No Maintenance is
Required.
Tighten the battery retainers on all of the batteries.

Tighten the battery retainers at every 1000 hours.
2. Turn the key for the battery disconnect switch to

the OFF position. Remove the key.
3. Disconnect the negative battery cable at the
battery disconnect switch. The battery disconnect
switch is connected to the machine frame.
Note: Do not allow the disconnected battery cable to
contact the battery disconnect switch or the machine.
4. Disconnect the negative battery cable from the
battery.
Check the following areas at a minimum interval

of 1000 hours. Check the following areas more
frequently during adverse conditions:
5. Disconnect the positive battery cable from the

battery.
1. The battery access cover is positioned on top of

the fuel tank. Open the battery access cover.
6. Inspect the battery terminals for corrosion. Inspect

the battery cables for wear or damage.
2. Clean the battery surface with a clean cloth.
7. If necessary, make repairs. If necessary, replace

the battery cable or the battery.
3. Maintain clean battery terminals. You may use

a coating of corrosion protection. Only use the
corrosion protection after the battery cable is
connected and after the battery cable is clean.
8. Connect the positive battery cable at the battery.

9. Connect the negative battery cable at the battery.
4. Coat the terminals with corrosion protection. Then,

install the post cover.
10. Connect the battery cable at the battery

disconnect switch.
5. For conventional batteries and low maintenance

batteries, follow these additional instructions:
11. Install the key for the battery disconnect switch.

Turn the battery disconnect switch to the ON
position.
Inspect the battery electrolyte level in each
battery cell. A maintenance free battery does

not require inspection.
84
Maintenance Section
Belts - Inspect/Adjust/Replace
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Belts - Inspect/Adjust/Replace
2. Adjust the belt until the correct belt tension is

reached. Tighten adjusting bolt (3) to 150 20 Nm
(110 15 lb ft).
SMCS Code: 1357-025; 1357-040; 1357-510
3. Tighten alternator bracket bolt (4).
i01742712
4. Check the tension of alternator belt (2).

5. If alternator belt (2) is not correctly adjusted repeat
Step 1 through Step 4.
6. Close access cover (1).
Air Conditioner Belt

Inspect the Belt
Illustration 106
g00708496
When the engine is stopped, open engine

compartment access cover (1) on the right side of
the machine.
Alternator Belt
Inspect the Belt
Illustration 108
g00871019
1. Inspect the condition and the adjustment of air

conditioner belt (5). Check the tension on the
belt. Measure the tension by using a Kent-Moore
Co. BT-33-97 gauge. A used compressor drive
belt should measure 445 44 N (100 10 lb). A
belt that has been in operation for 30 minutes or
more is a used belt. A new belt should measure
578 111 N (130 25 lb).
Illustration 107
g00870991
1. Inspect the condition and the adjustment of

alternator belt (2). Check the tension on the belt.
Measure the tension by using a Kent-Moore Co.
BT-33-109 gauge. A used compressor drive belt
should measure 667 44 N (150 10 lb). A
belt that has been in operation for 30 minutes or
more is a used belt. A new belt should measure
801 111 N (180 25 lb).
Adjust the Belt

1. Loosen alternator bracket bolt (4). Loosen
adjusting bolt (3).
Adjust the Belt

1. Loosen lock bolt (6) for the refrigerant compressor.
Loosen mounting bolt (7) for the refrigerant
compressor.
2. Pull the refrigerant compressor backward. Tighten
mounting bolt (7). Tighten lock bolt (6).
3. Check the tension of air conditioner belt (5).
4. If air conditioner belt (5) is not correctly adjusted
repeat Step 1 through Step 3.
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85
Maintenance Section
Blade Cushion Accumulator - Check
6. If you start the engine and poor cooling is still

experienced, turn off the air conditioner. Stop the
engine. Consult your Caterpillar dealer for air
conditioner system service, if necessary.
Fan Drive Belts
i01692015
Blade Lift Cylinder Socket Check/Adjust/Replace

SMCS Code: 5102-025; 5102-510; 5102-535;
5103-025; 5103-510; 5103-535
Inspect the Belts
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.
Illustration 109
g00871021
1. Inspect the condition of belts (8).

Note: If one belt or more than one belt is worn or
damaged, replace the belts in sets.
Fan drive belts (8) have a belt tightener that is
spring loaded. There is no adjustment for the fan
drive belts.
2. Inspect the condition of belt tightener and spring
(9). Lubricate the belt tightener at a regular
interval. Refer to Operation and Maintenance
Manual, Fan Drive Bearing and Belt Tightener Lubricate.
i01564804
Blade Cushion Accumulator Check

SMCS Code: 5077-535-BG
Consult your Caterpillar dealer for the following
information:
The correct checking procedure

The correct filling procedures
The recommended pressure
Illustration 110
g00871124
3. Remove the bolts (2) from the cap (1). Remove

the cap (1).
4. Remove one shim from either side of the inserts in
order to reduce clearance.
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.
86
Maintenance Section
Blade Lift Cylinder Socket - Lubricate
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i01342668
Blade Lift Cylinder Socket Lubricate

SMCS Code: 5102-086; 5103-086
for the blade lift cylinders. If a remote line becomes
damaged, install a fitting in place of the remote line
and lubricate the cylinders at the fitting until the line
can be replaced.
Wipe all the fittings before you apply lubricant to the
fittings.
Illustration 113
g00711650
The fittings for the blade lift cylinder (right side) are on the right
side of the machine.
Apply lubricant to fitting (4) in order to lubricate the lift

cylinder trunnion (right side). Apply lubricant to fitting
(5) in order to lubricate the lift cylinder trunnion (right
side). Apply lubricant to fitting (6) in order to lubricate
the lift cylinder yoke (right side).
Illustration 111
g00709762
Three lubrication fittings (1) are located on the left

side of the drawbar.
Illustration 114
g00711651
The fittings for the blade lift cylinder (left side) are on the left side
of the machine.
Apply lubricant to fitting (7) in order to lubricate the lift

cylinder trunnion (left side). Apply lubricant to fitting
(8) in order to lubricate the lift cylinder trunnion (left
side). Apply lubricant to fitting (9) in order to lubricate
the lift cylinder yoke (left side).
Illustration 112
g00709803
Apply lubricant to fitting (2) in order to lubricate the

ball joint of the right blade lift cylinder. Apply lubricant
to fitting (3) in order to lubricate the ball joint of the
left blade lift cylinder.
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87
Maintenance Section
Blade Tip Pin - Lubricate
i01358485
Blade Tip Pin - Lubricate

SMCS Code: 6060-086-PN; 6154-086-PN
Illustration 117
Illustration 115
g00716941
Two blade tip pins (1) are located behind the

moldboard on the circle. One pin is on the left side of
the circle and one pin is on the right side of the circle.
Only one pin is shown in the photo.
Illustration 116
g00713421
2. Alert indicator (1) for the brake oil pressure should

come on if the brake system is not at the normal
operating pressure.
3. Start the engine and run the engine for one minute
in order to increase the accumulator pressure.
Alert indicator (1) should go off. Stop the engine.
4. 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
minimum of five applications, until alert indicator
(1) comes on.
g00716942
Lubricate the fitting (2) on each of the two blade tip

pins.
i01352043
Brake Accumulator - Check

SMCS Code: 4263-535
Measure Pressure
1. Move the engine start switch key to the ON
position.
Illustration 118
g00714664
5. If alert indicator (1) comes on with less than

five applications of the service brake pedal,
measure the nitrogen precharge pressure of the
accumulators (2). Consult Systems Operation,
Testing and Adjusting, SENR1431, Brake
Accumulator - Test and Charge for the following
information: the correct checking procedure, the
correct filling procedure, and the recommended
pressure. Your Caterpillar dealer has the
appropriate tools for measuring the precharge
pressure of the brake accumulators. Only use dry
nitrogen gas to recharge the brake accumulators.
88
Maintenance Section
Brake Oil Filter - Replace
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i01368793
Brake Oil Filter - Replace
Note: Discard filter elements according to local

regulations.
4. Clean filter housing (2) and the base with clean,
nonflammable solvent. Make sure that all of the
old filter gasket has been removed.
SMCS Code: 4295-510
5. Install the new filter element in the housing. Install

the housing and the element.
6. Close access door (1).
i01368807
Brake Oil Screen Clean/Replace

SMCS Code: 4295-070; 4295-510
Illustration 119
g00722069
1. Open access door (1).
Illustration 121
g00722069

Illustration 120
g00722100
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
2. Remove filter housing (2) and the element.
3. Inspect the filter element. Refer to Operation and
Maintenance Manual, Oil Filter - Inspect.
NOTICE
products.
mandates.
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Maintenance Section
Brakes, Indicators and Gauges - Test
i01695214
Brakes, Indicators and Gauges

- Test
SMCS Code: 4251-081; 4267-081; 4269-081;
7000-081; 7450-081; 7490-081
Illustration 122
g00722147
2. Remove screen housing (2) and the screen.

3. Clean the screen with clean, nonflammable
solvent.
4. Inspect the screen. Replace the screen if the
screen is damaged.
regulations.
5. Clean screen housing (2) and the base with clean,
nonflammable solvent.
6. Install the screen in the housing. Install the
housing and the screen.
Illustration 123
g00872895
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 forward horn.
Move the machine forward and test the service
brakes. If the service brakes do not function properly,
see Operation and Maintenance Manual, Braking
System - Test in the Maintenance Interval Schedule
of this manual.
Stop the engine.
Make any needed repairs before you operate the
machine.
90
Maintenance Section
Braking System - Test
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i01692077
Braking System - Test

SMCS Code: 3077-081; 4011-081; 4250-081;
4251-081; 4267-081
Service Brake Holding Ability Test
Personal injury can result if the machine moves

while testing.
If the machine begins to move during test, reduce
the engine speed immediately and engage the
parking brake.
Make sure that the area around the machine is clear
of personnel and clear of obstacles.
Test the service brake on a dry, level surface.
Fasten your seat belt before you test the brakes.
Use the following test in order to determine whether
the service brake is functional. This test is not
intended to measure the maximum holding ability of
the service brake.
Illustration 125
g00872901
3. Move the transmission direction and speed control

(5) to the THIRD SPEED FORWARD position.
Increase the engine speed to high idle.
4. Gradually release transmission modulator pedal
(3). The machine should not move.
NOTICE
If the machine begins to move, reduce the engine
speed immediately and engage the parking brake.
5. Reduce the engine speed to low idle. Engage
parking brake control (4). Lower the blade to the
ground. Stop the engine.
NOTICE
If the machine moved while testing the service brake
consult your Caterpillar dealer.
Have the dealer inspect and, if necessary, repair the
service brakes before returning the machine to operation.
Illustration 124
g00713520
1. Disconnect sensor (1) from service brake pedal

(2).
Note: Disconnecting the sensor prevents the
transmission from disengagement.
2. Start the engine. Raise the blade slightly. Depress
transmission modulator pedal (3). Apply the
service brake (2).
Note: The friction material for the brake may require

replacement. The new friction material for the brake
may need to be burnished for maximum performance.
For the procedure to burnish the new friction material
for the brake, consult your Caterpillar dealer or see
Special Instruction, SEHS9143, Burnishing The
Secondary Brake Shoes.
Parking Brake Holding Ability Test
Personal injury can result if the machine moves

while testing.
It the machine begins to move during test, reduce
the engine speed immediately and engage the service brake control.
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91
Maintenance Section
Cab Air Filter - Clean/Replace
Be sure that the area around the machine is clear of

personnel and clear of obstacles.
The outside air filter is located behind the operators

compartment.
Test the parking brake on a hard, dry surface.
1. Remove filter cover (1).
Fasten your seat belt before you test the parking

brake.
Use the following test to determine whether the
parking brake is functional. This test is not intended
to measure the maximum holding ability of the
parking brake.
1. Position the machine on a slope of 20 percent.
2. Apply service brake control pedal (2). With
transmission direction and speed control (5) in the
NEUTRAL position, engage parking brake control
(4). Release service brake control pedal (2). The
wheels should not rotate. If the wheels rotate,
engage the service brake control pedal (2).
NOTICE
If the machine moved while testing the parking brake,
Have the dealer inspect and, if necessary repair the
parking brake before returning the machine to operation.
Illustration 127
g00697321
2. Remove filter element (2). Clean filter element (2)

with pressure air or wash filter element (2) in warm
water and a nonsudsing household detergent.
3. Rinse element (2) in clean water and allow
element (2) to dry completely.
4. Install filter element (2).
5. Install filter cover (1).
i01317125
Cab Air Filter - Clean/Replace

SMCS Code: 7311-070-FI; 7311-510-FI; 7342-070;
7342-510
Outside Filters (Fresh Air)

Note: Clean the filters daily in dusty conditions.
Change filters
Note: Change the filters when the filters are no
longer able to be cleaned.
2. Remove filter elements (2) and discard the
elements.
3. Install the new filter elements.
Clean Filters
4. Replace filter cover (1).
Recirculation Air Filter

Clean Filters
Note: Clean the filters daily in dusty conditions.
Illustration 126
g00697319
92
Maintenance Section
Centershift Cylinder Socket - Check/Adjust/Replace
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i01692090
Centershift Cylinder Socket Check/Adjust/Replace

SMCS Code: 5223-023; 5223-025; 5223-535
1. Rotate the blade. Place the blade at an angle of
90 degrees to the frame. Lower the blade to the
ground.
2. Operate the centershift cylinder. Observe the
socket. If the socket moves without movement of
the drawbar, adjustment is necessary.
Illustration 128
g00697323
Air filter (3) is located behind the operators seat.
Illustration 130
Illustration 129
g00697324
g00871159
3. Remove the bolts (1) from the cap. Remove the

cap (2).
4. Remove one shim from either side of the inserts in

order to reduce clearance.
2. Remove the filter element. Clean the filter element

with pressure air or wash the element in warm
water and a nonsudsing household detergent.
Note: If you need to remove two shims, then remove

one shim from each side of the inserts.
3. Rinse the element in clean water. Allow the

element to dry completely.
4. Install the filter element.
5. Install filter cover (4).
Change Filters
Note: Change the filters when the filters are no
longer able to be cleaned.
2. Remove the filter element and discard the
element.
3. Install the new filter element.
4. Replace filter cover (4).
5. Install the cap and 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 socket. Add additional
shims, as needed.
SEBU6907-09
93
Maintenance Section
Centershift Cylinder Socket - Lubricate
i01342425
Centershift Cylinder Socket Lubricate

SMCS Code: 5223-086
for the center shift cylinder. If a remote line becomes
and lubricate the cylinders at the fitting until the line
can be replaced.
fittings.
Illustration 133
g00711669
The fittings for the centershift cylinder are on the left side of the
machine.
Apply lubricant to fitting (3) in order to lubricate the

centershift cylinder mounting. Apply lubricant to fitting
(4) in order to lubricate the trunnion for the centershift
cylinder. Apply lubricant to fitting (5) in order to
lubricate the trunnion for the centershift cylinder.
i02564685
Circle Clearances Check/Adjust

Illustration 131
g00709762
Three lubrication fittings (1) are located on the left

side of the drawbar.
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

90 degrees to the frame.
Note: Install the C-clamps (not shown) before you
lower the blade to the ground.
Illustration 132
g00709740
In order to lubricate the ball joint of the center shift

cylinder, apply lubricant to fitting (2).
Illustration 134
g00715536
94
Maintenance Section
Circle Clearances - Check/Adjust
SEBU6907-09
2. Clamp two C-clamps onto the front of blade circle

(2) and drawbar (1). This will fasten the blade
circle and the drawbar together. Tighten the two
C-clamps until wear strips (3) are in contact with
the top of the blade circle and with the bottom of
the drawbar.
3. Lower the blade to the ground.
4. Engage the parking brake. Stop the engine.
Illustration 136
g00715737
2. Check wear strips (3) around the entire

circumference of blade circle (2). The wear strips
should be in complete contact with the blade circle
and the drawbar.
3. Shoe mounting bolt (9), shoe mounting bolt (10)
and shoe mounting bolt (11) must be tight. Make
sure that wear strips (3) are completely seated
in circle shoes (8).
Illustration 135
g00715760
5. Measure distance (A) between the top surface

of the blade circle and the bottom surface of the
drawbar. Replace wear strip (3) if the distance is
less than 1.5 mm (0.06 inch).
6. Inspect wear strip (3). Inspect the drawbar. The
wear strip should be in complete contact at all
points with the blade circle. If the wear strip is not
in complete contact with the blade circle, shims
(5) can be used. If wear strip (3) is not in complete
contact with the blade circle, replace the wear
strip.
Blade Circle and Shoe

1. Perform Step 1 through Step 4 in Blade Circle
and Drawbar.
4. Measure the distance between the bottom of

blade circle (2) and the top of shoe wear strip (4).
Maintain an approximate clearance of 0.5 mm
(0.02 inch). Maintain the proper clearance by
adding shims (5) or by removing shims (5).
Note: The proper clearance will permit the blade
circle to freely rotate for 360 degrees.
Adjust circle shoes (8) one at a time.
5. Loosen locknuts (6) and remove the shoe
mounting bolts.
6. Add shims (5) or remove shims (5), as required.
7. Install the shoe mounting bolts and tighten
locknuts (6).
8. Check the clearance after each circle shoe (8)
has been adjusted for proper clearance. Make
adjustments, if necessary.
Note: After all adjustments have been made, the
blade circle must rotate freely without binding.
Circle Pinion and Circle Shoe

Note: The engagement of the circle pinion and tooth
segment (12) is affected by the adjustment of circle
shoes (8).
90 degrees to the frame.
SEBU6907-09
95
Maintenance Section
2. Lower the blade to the ground.

3. Apply the service brake as you slowly inch the
machine in a forward direction. This will hold a
light load between shoe wear strips (4) for the
front circle shoes and blade circle (2).
4. Engage the parking brake. Stop the engine.
5. Loosen the following components on each of
the circle shoes: shoe mounting bolt (9), shoe
mounting bolt (10), shoe mounting bolt (11), and
locknuts (6).
6. Follow one of the following three procedures
to center the blade circle on your machine.
Serial Numbers 7KK312-Up
4. Once the blade circle is centered, turn adjustment

screws (7) on the front circle shoes and the rear
circle shoes until the measurement between the
tip of tooth segment (12) and machined lip (13) at
the front of the blade circle is 3.0 mm (0.12 inch)
larger than the measurement at the rear of the
blade circle. For example, if the blade circle is
centered and all of the measurements are equal
at 9.0 mm (0.35 inch), turn adjustment screws
(7) until the measurement at the front of the
blade circle equals 10.5 mm (0.41 inch) and the
measurement at the rear of the blade circle equals
7.5 mm (0.30 inch).
Note: If the correct measurement cannot be obtained
due to worn shoe wear strips, replace the worn shoe
wear strips and repeat the procedure.
Note: Adjustment screws (7) must be tight against
circle shoes (8) before you tighten the shoe mounting
bolts and locknuts (6).
5. Tighten the shoe mounting bolts and the locknuts
for the front circle shoes.
6. When the pinion clearance is set and the front
circle shoes are in contact with the blade circle,
measure distance (B) between each shoe wear
strip (4) and blade circle (2). The distance should
be no more than 0.8 mm (0.03 inch).
g00716011
7. Tighten all shoe mounting bolts to 1150 100 Nm

(840 75 lb ft). Tighten all locknuts to a torque of
500 65 Nm (369 48 lb ft).
1. At four different locations on the blade circle (front,

rear, left and right), measure the distance between
the tip of tooth segment (12) and machined lip
(13). Record the four measurements.
8. Lubricate the circle pinion and tooth segments

(12). Refer to Operation and Maintenance Manual,
Circle Drive Pinion Teeth - Lubricate for the
proper procedure.
Note: When the blade circle is centered, the left

measurement and the right measurement will be
equal. When the blade circle is centered, the front
measurement and the rear measurement will be
equal.
Serial Numbers 7KK40-311
Illustration 137
2. If the measurements are different, tighten

adjustment screws (7) or loosen adjustment
screws (7) in order to change the position of the
blade circle. Record the four measurements again.
3. Repeat Step 2 until the blade circle is centered on
the machine.
Illustration 138
g00716011
96
Maintenance Section

equal.
the machine.
tip of tooth segment (12) and machined lip (13) at
the front of the blade circle is 3.0 mm (0.12 inch)
larger than the measurement at the rear of the
blade circle. For example, if the blade circle is
centered and all of the measurements are equal
at 9.0 mm (0.35 inch), turn adjustment screws
(7) until the measurement at the front of the
blade circle equals 10.5 mm (0.41 inch) and the
measurement at the rear of the blade circle equals
7.5 mm (0.30 inch).
500 65 Nm (369 48 lb ft).
proper procedure.
SEBU6907-09
Serial Numbers 7KK1-39

equal.
the machine.
Illustration 139
g00716022

inside edge of blade circle (2) and the outside
edge of circle drive housing (14) is 3.0 mm
(0.12 inch) larger than the measurement at the
rear of the blade circle. For example, if the blade
circle is centered and all of the measurements
are equal at 9.0 mm (0.35 inch), turn adjustment
screws (7) until the measurement at the front of
the blade circle equals 10.5 mm (0.41 inch) and
the measurement at the rear of the blade circle
equals 7.5 mm (0.30 inch).
SEBU6907-09
97
Maintenance Section
Circle Drive Oil - Change

500 65 Nm (369 48 lb ft).
proper procedure.
Illustration 141
g00130693
i01863845
Circle Drive Oil - Change
1. Remove drain plug (1). Remove check/fill plug (2).

Allow the oil to drain into a suitable container.
SMCS Code: 5207-510-OC
2. Clean the drain plug and install the drain plug.
NOTICE
3. Fill the circle drive housing with oil. See Operation

and Maintenance Manual, Capacities (Refill).

products.
4. Clean the check/fill plug and install the check/fill

plug.
5. Repeat Step 1 through Step 4 for the other circle
drive housing.
6. Start the engine. Operate the machine for a few
minutes. Check the circle drive housings for leaks.

mandates.
7. Stop the engine. Remove the check/fill plugs and

check the oil level for each circle drive housing.
Maintain the oil level to the bottom of the filler
openings. If necessary, add oil.
Clean the area around each drain plug and clean the
area around each check/fill plug before you remove
the plugs.
8. Install the check/fill plugs.

i01692226
Circle Drive Oil Level - Check

SMCS Code: 5207-535-OC
If a leak develops or you suspect a leak, check the
oil level.
There are two circle drive housings. One of the circle
drive housings is located at the front of the circle
drive. The other circle drive housing is located at the
rear of the circle drive.
Illustration 140
g00130691
One circle drive housing is located at the front of the circle drive.
One circle drive housing is located at the rear of the circle drive.
Wipe the surfaces around the opening for the

check/fill plug before you check the oil and before
you add oil.
The check/fill plug is located on top of the circle drive
housing at the front of the circle.
98
Maintenance Section
Circle Drive Pinion Teeth - Lubricate
Illustration 142
SEBU6907-09
g00775433
1. Remove check/fill plug (1).

2. Maintain the oil level to the bottom of the opening
for the check/fill plug.
3. Install check/fill plug (1).
4. Repeat Step 1 through Step 3 for the remaining
circle drive housing.
i01446507
Circle Drive Pinion Teeth Lubricate

SMCS Code: 5207-086-PI
Illustration 144
g00698039
1. Clean the dirt and the old lubricant from the blade
circle and from the circle drive pinion teeth.
2. Apply molybdenum disulfide grease to the
blade circle and to the circle drive pinion teeth.
Caterpillar Auto Lube 2 is recommended. There
are two circle drive pinions (2).
i01863840
Circle Top - Lubricate

SMCS Code: 6154-086-TP
Contact with a moving attachment may cause injury or death.

Avoid contact with a moving attachment when lubricating or maintaining the attachment.
1. Park the machine on a level surface and engage
the parking brake.
2. Run the engine and raise the blade. Do not raise
the blade too high. Raise the blade enough to
clear the surface.
Illustration 143
g00698035
(1) One circle drive pinion is located at the front of the circle drive
and one circle drive pinion is located at the rear of the circle
drive.
Illustration 145
g00871231
SEBU6907-09
99
Maintenance Section
Circuit Breakers - Reset
3. Remove covers (1). There are a total of four

covers for the lubrication points. There are two
lubrication points on each side of the circle.
4. Rotate the blade circle and apply a dry film
lubricant to the top of the blade circle. See Special
Publication, SEBU6250, Caterpillar Machine
Fluid Recommedations, Dry Film Lubricant.
i01318973
Circuit Breakers - Reset
i01367472
Condenser (Refrigerant) Clean

SMCS Code: 1805-070
NOTICE
If excessively dirty, clean condenser with a brush. To
prevent damage or bending of the fins, do not use a
stiff brush.
Repair the fins if found defective.
SMCS Code: 1417-529; 1420-529

Circuit Breaker Reset Push the button
inward in order to reset the circuit breakers.
If the system is working properly, the button
will remain depressed. If the button does not remain
depressed, check the appropriate electrical circuit.
Illustration 147
g00714817
1. Remove access panel (1) at the rear of the

machine.
Illustration 146
g00698331
Alternator (1) 105 AMP
Engine (2) 25 AMP
Brake Retract (3) 5 AMP

Illustration 148
g00721435
Battery (Right side) (4)
2. Refrigerant condenser (2) is located behind the

radiator at the rear of the machine. Inspect the
condenser for debris. If necessary, clean the
condenser.
Battery (Left side) (5)
3. Use clean water in order to wash off all dust and

dirt from the condenser.
Flexxaire Fan (6) (if equipped)
4. Replace access panel (1).
100
Maintenance Section
Cooling System Coolant (ELC) - Change
SEBU6907-09
i01863846
Cooling System Coolant (ELC)

- Change
SMCS Code: 1350-044-NL; 1350-544-NL;
1395-044-NL
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
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.
NOTICE
products.
mandates.
If the coolant in the machine is changed to Extended
Life Coolant from another type of coolant, see Special
Publication, SEBU6250, Extended Life Coolant
Cooling System Maintenance.
Drain the coolant whenever the coolant is dirty or
whenever foaming is observed.
Cooling System Coolant Additive contains alkali.

Avoid contact with skin and eyes.
NOTICE
Mixing ELC with other products reduces the effectiveness of the coolant and shortens coolant life. Use only
Caterpillar products or commercial products that have
passed the Caterpillar EC-1 specifications for premixed or concentrate coolants. Use only Caterpillar
Extender with Caterpillar ELC. Failure to follow these
recommendations could result in the damage to cooling systems components.
If ELC cooling system contamination occurs see the
topic Extended Life Coolant (ELC) in the Operation
and Maintenance Manual, SEBU6250, Caterpillar
Machine Fluids Recommendations.
Illustration 149
g00871303
1. Slowly loosen pressure cap (1) in order to relieve

system pressure. Remove pressure cap (1).
Illustration 150
g00871304
SEBU6907-09
2. Drain valve (2) is located on the left side of the

machine under the radiator. Remove the front
bottom guard in order to properly access the drain.
Open drain valve (2). Allow the coolant to drain
into a suitable container.
3. Close drain valve (2). Fill the cooling system with
a solution which consists of clean water and of
cooling system cleaner. The concentration of the
cooling system cleaner should be 6 to 10 percent.
4. Start the engine. Run the engine for 90 minutes.
Stop the engine. Drain the cleaning solution into a
suitable container.
5. While the engine is stopped, flush the system with
water. Flush the system until the draining water
is clean.
6. Close drain valve (2).
7. Install the front bottom guard.
8. Add the coolant solution. See the following topics:
101
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
i01863850
Cooling System Coolant

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

and alkali.
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.
Special Publication, SEBU6250, Caterpillar

burns.
Operation and Maintenance Manual, Lubricant
Cooling System Coolant Additive contains alkali.

Avoid contact with skin and eyes.
Machine Fluids Recommendations

Viscosities
Operation and Maintenance Manual, Capacities

(Refill)
Note: If you are using Caterpillar antifreeze, do

not add the supplemental coolant additive at this
time. Also, do not change the supplemental coolant
additive element at this time.
9. Start the engine. Run the engine without the
pressure cap until the thermostat opens and the
coolant level stabilizes.
10. Maintain the coolant level within 13.0 mm
(0.50 inches) of the bottom of the filler pipe.
11. Install the pressure cap. If the gasket is damaged,
replace the pressure cap.
12. Stop the engine.
NOTICE
products.
mandates.
When a Caterpillar Extended Life Coolant (ELC)
is used, an extender must be added to the cooling
system. See the Operation and Maintenance
Manual, Maintenance Interval Schedule for the
proper service interval. The amount of extender is
determined by the cooling system capacity.
1. Stop the engine and allow the engine to cool.
102
Maintenance Section
Cooling System Level - Check
SEBU6907-09
i01692449
Cooling System Level - Check

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

and alkali.
Illustration 151
g00871303
2. Open the cover. Remove the cooling system

pressure cap (1) slowly in order to relieve the
pressure.
3. Drain some coolant from the radiator into a
suitable container. This will allow space for
additional cooling system coolant extender.
4. In order to add cooling system coolant extender,
refer to the Special Publication, SEBU6250,
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.
5. Install the cooling system pressure cap (1). Close
the cover.

Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool
enough to touch with your bare hand.
burns.
Cooling System Conditioner contains alkali. Avoid
contact with skin and eyes.
The sight gauge for the cooling system is located on
the left side of the machine at the rear of the machine.
Illustration 152
g00713862
1. Maintain coolant level so that coolant is visible in

sight gauge (1).
SEBU6907-09
Illustration 153
103
Maintenance Section
Cooling System Pressure Cap - Clean/Replace
g00698621
2. If necessary, add the appropriate coolant mixture.

Open the cover. Remove filler cap (2) slowly in
order to relieve pressure. Add coolant through the
filler tube.
3. Install filler cap (2). Close the cover.
i01692462
Cooling System Pressure Cap

- Clean/Replace
SMCS Code: 1382-070; 1382-510

and alkali.
burns.
Illustration 154
g00871303
1. Remove pressure cap (1) slowly in order to relieve

pressure.
2. Inspect pressure cap (1) and the cap seal for
damage, deposits, and foreign material. Clean
pressure cap (1) with a clean cloth. Replace
pressure cap (1) if pressure cap (1) is damaged.
3. Install cap (1).
i00350379
Cooling System Water

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

and alkali.
burns.
104
Maintenance Section
Crankshaft Vibration Damper - Clean
Replace the cooling system water temperature

regulator on a regular basis in order to reduce the
chance of unscheduled downtime and of problems
with the cooling system.
The water temperature regulator should be replaced
after the cooling system has been cleaned. Replace
the water temperature regulator while the cooling
system is completely drained or while the cooling
system coolant is drained to a level that is below the
water temperature regulator housing assembly.
SEBU6907-09
6. Add the cooling system coolant. Maintain the

coolant level within 13 mm (.5 inch) of the bottom
of the filler tube.
i01794213
Crankshaft Vibration Damper

- Clean
SMCS Code: 1205-070
NOTICE
Failure to replace the engines water temperature regulator on a regularly scheduled basis could cause severe engine damage.
Note: If you are only replacing the water temperature
regulator, drain the cooling system coolant to a level
that is below the water temperature regulator housing
assembly.
1. Loosen the hose clamp and remove the hose from
the water temperature regulator housing.
2. Remove the bolts from the water temperature
regulator housing and remove the water
temperature regulator housing.
3. Remove the gasket and remove the water
temperature regulator from the water temperature
regulator housing.
NOTICE
Former water temperature regulators may be used, if
they meet test specifications and are not damaged or
have excessive buildup or deposits.
NOTICE
Since Caterpillar engines incorporate a shunt design
cooling system, it is mandatory to always operate the
engine with a water temperature regulator.
Depending on load, failure to operate with a water
temperature regulator could result in either an overheating or an overcooling condition.
NOTICE
If the water temperature regulator is installed incorrectly, it will cause the engine to overheat.
4. Install a new water temperature regulator and
a new gasket. Install the water temperature
regulator housing.
5. Install the water temperature regulator housing
and the hose. Tighten the hose clamp.
Illustration 155
g00918281
Use a high pressure washer in order to clean the dirt,

the mud and the debris from the crankshaft vibration
damper.
Note: Excessive dirt and mud can cause unwanted
vibration.
i01353557
Crankshaft Vibration Damper

- Inspect
SMCS Code: 1205-040
Damage to the vibration damper or failure of the
vibration damper will increase torsional vibrations.
These vibrations will result in damage to the
crankshaft and to the other engine components. A
deteriorating vibration damper will cause excessive
gear train noise at variable points in the speed range.
SEBU6907-09
105
Maintenance Section
Cutting Edges and End Bits - Inspect/Replace
i01569254
Cutting Edges and End Bits Inspect/Replace

SMCS Code: 6801-040; 6801-510; 6804-040;
6804-510
Personal injury or death can result from the blade

falling.
Block the blade before changing blade tips.
Illustration 156
g00714351
Caterpillar recommends replacing vibration damper

(1) for any of the following reasons:
The engine has had a failure because of a broken

crankshaft.
The SOS analysis detected a worn crankshaft

front bearing.
The SOS analysis detected a large amount of
gear train wear that is not caused by a lack of oil.
Fluid leakage is detected during inspection.

The housing is damaged.
Refer to Disassembly and Assembly, SENR1436,
Damper & Crankshaft Pulley for the procedure to
remove the damper and 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.
Note: Contact your Caterpillar Dealer for further
information.
Illustration 157
g00811262
End bits (1) and/or cutting edges (2) may be

damaged. End bits (1) and/or cutting edges (2) may
be worn excessively. Replace the end bits (1) and/or
the cutting edges (2), as needed.
1. Place blocks under the blade. Lower the blade
onto the blocks. Do not block up the blade too
high. Just use enough blocks so that end bits (1)
and cutting edges (2) can be removed.
2. Remove end bits (1) and/or cutting edges (2).
3. Install new end bits (1) and/or new cutting edges
(2).
4. Raise the blade and remove the blocks.
106
Maintenance Section
Differential Oil Filter - Replace
SEBU6907-09
i01368552
Differential Oil Filter - Replace

regulations.
4. Clean the filter base with clean, nonflammable
solvent. Make sure that all of the old filter gasket
has been removed.
SMCS Code: 3258-510-FI
5. Install the new filter assembly.

i01705561
Differential Thrust Pin

Clearance - Check
SMCS Code: 3258-535-T9; 3258; 3260; 3284
Illustration 158
g00722069
Illustration 160
g00710712
The differential thrust pin is located on the left side

of the rear axle housing.
Illustration 159
g00721968
NOTICE
products.
mandates.
2. Remove filter assembly (2).
3. Inspect the filter element. Refer to Operation and
Maintenance Manual, Oil Filter - Inspect.
For the correct thrust pin adjustment procedures,

refer to Disassembly and Assembly, SENR1437,
Differential, Bevel Gear and Pinion or see your
Caterpillar dealer.
i01348438
Drawbar Ball and Socket Lubricate

SMCS Code: 6170-086; 6171-086
for the drawbar ball and socket. If a remote line
remote line and lubricate the drawbar ball and socket
Wipe the fitting before you apply lubricant to the
fitting.
SEBU6907-09
107
Maintenance Section
Drawbar Ball and Socket End Play - Check/Adjust
Adjust
1. Support the drawbar and support the circle.
2. Remove the eight bolts (1) that hold the drawbar
to the bolster. Move the drawbar backward or
move the machine forward.
Illustration 161
g00711680
The fitting for the drawbar ball and socket is located

on the front frame at the right front of the machine.
Lubricate fitting (1) in order to lubricate the drawbar
ball and socket.
i01324908
Illustration 163
g00701356
Drawbar Ball and Socket End

Play - Check/Adjust
3. Remove the two capscrews (2) from the cap

(4) that holds the drawbar and the adapter (6)
together. Remove the adapter.
SMCS Code: 6170-025; 6170-535; 6171-025;

6171-535
4. As required, remove the shims (5) or install

the shims (5) in order to attain an end play of
0.6 0.2 mm (.02 .01 inch).
Check
Rotate the blade so that the blade is placed at an
angle of 90 degrees to the frame. Lower the blade to
the ground. While you maintain a light load between
the ball and the socket, inch the machine slowly to
the rear. Stop the machine and shut off the engine.
5. Install the two capscrews (2) in the cap (4) and

adapter (6). Rotate the cap (4) by hand. The
socket should rotate freely on the ball (3).
Illustration 164
Illustration 162
g00701353
Location of drawbar ball and socket
Measure the end play that is between the ball (3) and
the cap (4). The end play should be 0.6 0.2 mm
(.02 .01 inch). Adjust the end play, if necessary.
g00701357
6. Check the torque on the eight bolts (7) that

hold the ball (3) in place. The correct torque is
900 100 Nm (664 74 lb ft).
7. Assemble the drawbar to the bolster. Tighten the
eight bolts (1) to a torque of 1800 200 Nm
(1328 148 lb ft).
108
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
i01692502
Engine Air Filter Primary

Element - Clean/Replace
SMCS Code: 1051-070-PY; 1051-510-PY;
1054-070-PY; 1054-510-PY
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.
Service the air cleaner filter element when the
yellow piston on the engine air filter service
indicator enters the red zone or the indicator
reads 63.5 cm (25 inch) of water. Refer to
Operation and Maintenance Manual, Engine Air
Filter Service Indicator - Inspect.
1. Open the access door for the air filter housing.
SEBU6907-09
If the yellow piston in the indicator moves into the red

zone after starting the engine or the exhaust smoke
is still black after installation of a clean primary filter
element, install a new primary filter element. If the
piston remains in the red zone replace the secondary
element.
Cleaning Primary Air Filter

Elements
NOTICE
Caterpillar recommends certified air filter cleaning services 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 remove dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets, or
seals. Dirt entering the engine will cause damage to
engine components.
Illustration 165
g00102316
2. Remove cover (1) for the air filter housing .

3. Remove primary filter element (2) from the air
filter housing.
4. Clean the inside of the air filter housing.
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. Reset the engine air filter service indicator.
8. Close the access door.
The primary air filter element can be used up to

six times if the element is properly cleaned and
inspected. When the primary air filter element is
cleaned, check for rips or tears in the filter material.
The primary air filter element should be replaced at
least one time per year. This replacement should be
performed regardless of the number of cleanings.
NOTICE
Do not clean the air filter elements by bumping or tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets, or seals. Damaged 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
SEBU6907-09
109
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
Inspecting the Primary Air Filter

Elements
Vacuum cleaning
Pressurized Air
Pressurized air can be used to clean primary air filter
elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi).
Illustration 167
Illustration 166
g00281692
Note: When the primary air filter elements are

cleaned, always begin with the clean side (inside)
in order to force dirt particles toward the dirty side
(outside).
Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent
damage to the paper pleats. Do not aim the stream of
air directly at the primary air filter element. Dirt could
be forced further into the pleats.
Vacuum Cleaning
Vacuum cleaning is another method for cleaning
primary air filter elements which require daily cleaning
because of a dry, dusty environment. Cleaning with
pressurized air is recommended prior to vacuum
cleaning. Vacuum cleaning will not remove deposits
of carbon and oil.
g00281693
Inspect the clean, dry primary air filter element. Use

a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air filter
element. Rotate the primary air filter element. Inspect
the primary air filter element for tears and/or holes.
Inspect the primary air filter element for light that may
show through the filter material. If it is necessary in
order to confirm the result, compare the primary air
filter element to a new primary air filter element that
has the same part number.
Do not use a primary air filter element that has any
tears and/or holes in the filter material. Do not use
a primary air filter element with damaged pleats,
gaskets or seals. Discard damaged primary air filter
elements.
Storing Primary Air Filter Elements

If a primary air filter element that passes inspection
will not be used, the primary air filter element can
be stored for future use.
Illustration 168
g00281694
110
Maintenance Section
Engine Air Filter Secondary Element - Replace
SEBU6907-09
Do not use paint, a waterproof cover, or plastic as a

protective covering for storage. An airflow restriction
may result. To protect against dirt and damage, wrap
the primary air filter elements in Volatile Corrosion
Inhibited (VCI) paper.
3. Cover the air inlet opening. Clean the inside of

the air cleaner housing.
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:
5. Install the primary element and the air cleaner

cover.
Date of cleaning
4. Uncover the air inlet opening. Install a new

secondary element.
6. Close the left side engine compartment door, if

equipped.
Note: When you replace the air filter element, you
must replace the filter screen. Refer to Operation
and Maintenance Manual, Engine Air Filter Service
Indicator Screen - Check/Replace.
Number of cleanings
Store the box in a dry location.
i01341132
i01692537
Engine Air Filter Secondary

Element - Replace
Engine Air Filter Service

Indicator - Inspect
SMCS Code: 1051-510-SE; 1054-510-SE
SMCS Code: 7452-040; 7452-040-DJ;

7452-040-ENG
NOTICE
Always replace the secondary element. Do not attempt to reuse it by cleaning. Engine damage could
result.
Note: Replace the engine air filter secondary element
when you service the engine air filter primary element
for the third time. Replace the secondary element
if the exhaust smoke remains black and a clean
primary element has been installed. Also, replace
the secondary element if the element has been in
service for one year.
1. Reset the engine air filter service indicator.

2. Start the engine.
3. Run the engine at high idle.
1. Open the left side engine compartment access

door, if equipped. Remove the air cleaner cover
and the primary element.
Illustration 170
Illustration 169
2. Remove the secondary element.
g00039214
g00713872
SEBU6907-09
111
Maintenance Section
Engine Air Filter Service Indicator - Inspect/Replace
Illustration 171
g00701455
5. If the yellow piston in the engine air filter service

indicator (2) enters the red zone, stop the engine
and service the air cleaner.
If the yellow piston in the engine air filter service
indicator (2) does not enter the red zone, the air
cleaner does not require service at this time.
6. Stop the engine.
Note: See the Operation and Maintenance Manual,
Engine Air Filter Primary Element - Clean/Replace.
See the Operation and Maintenance Manual, Engine
Air Filter Secondary Element - Replace.
Note: Refer to Operations and Maintenance Manual,
Engine Air Filter Service Indicator - Inspect/Replace
in order to determine if an engine air filter service
indicator is faulty.
i01334212

Indicator - Inspect/Replace
SMCS Code: 7452-040; 7452-510
Illustration 173
g00701455
2. Stop the engine. Check the operation of service

indicator (2) by pressing the reset button on the
bottom of service indicator (2). This should require
three pushes or less of the reset button.
3. Next, check the movement of the yellow piston
in service indicator (2). Start the engine and
accelerate the engine to high idle for a few
seconds. After the governor control pedal is
released, the yellow piston should remain at
the highest position that was achieved during
acceleration.
Note: The air filter indicator should be replaced
during engine overhauls. The air filter indicator should
also be replaced during replacement of any major
engine component . Replace the air filter indicator at
least one time per year.
4. If the indicator will not reset easily, replace service
indicator (2). If the yellow piston of the indicator
will not latch at the highest vacuum that is
attained, replace service indicator (2). Tighten the
indicator to a torque of 2 Nm (18 lb in). Excessive
tightening force may crack the top of the indicator.
For more information on the air filter indicator,
refer to Video Tape, PEVN1736, Caterpillar Air
Filter Service Indicator.
Note: If the indicator does not reset, the filter in
the restriction sensing hole of the air filter may be
plugged.
Illustration 172
g00713872
112
Maintenance Section
Engine Air Filter Service Indicator Screen - Check/Replace
i01357407

Indicator Screen Check/Replace
SEBU6907-09
2. A 2 inch piece of 1/8 inch drill rod is needed in

order to push filter screen (1) from the inside of
the elbow to the outside.
3. After the plugged filter screen (1) has been
removed, install a new filter screen (1) in the hole
on the outside of the elbow. Use a piece of 1/4
inch drill rod to lightly seat the filter element in the
bottom of the bore.
SMCS Code: 7452-510-Z3; 7452-535-Z3
i01550089
Engine Air Precleaner - Clean

SMCS Code: 1055-070; 1055-070-DJ
NOTICE
Service the engine air precleaner only with the engine
stopped. Engine damage could result.
The engine air precleaner is positioned on top of the
engine compartment.
Illustration 174
g00716331
Check
1. Set an 8N-2694 Air Filter Service Indicator to
indicate a restricted air cleaner.
2. Screw the indicator onto a 1/8 inch NPT pipe
nipple.
Illustration 175
3. Screw the other end of the nipple into the threaded

hole in the elbow. Normally, filter screen (1) is
located in the elbow.
4. Depress the reset button on the 8N-2694 Air
Filter Service Indicator.
5. If the indicator resets, filter screen (1) is not
plugged. If the indicator does not reset, filter
screen (1) is plugged. Filter screen (1) should
then be replaced.
Replace
1. Remove the air cleaner from the air cleaner
housing. Removing the air cleaner from the air
cleaner housing will provide access to the hole
inside the elbow. Filter screen (1) is installed
inside the elbow.
g00805907
1. Loosen clamp (1) at the bottom of engine air

precleaner (2).
2. Remove engine air precleaner (2) and inspect the
opening for dirt and debris. Clean the tubes, if
necessary.
3. Clean engine air precleaner (2) with pressure air
or wash the engine air precleaner (2) in clean
warm water.
4. Install engine air precleaner (2). Tighten clamp (1).
SEBU6907-09
113
Maintenance Section
Engine Crankcase Breather - Clean
i01325724
Engine Crankcase Breather Clean
7. Inspect the hose for damage. If the hose is

damaged, replace the hose.
8. Install the engine crankcase breather (3). Tighten
clamp (4) to 4.5 0.5 Nm (40.00 4.40 lb in).
SMCS Code: 1000-070-BRE; 1317-070;

1317-070-DJ
9. Install the hose and clamp (2).
The engine crankcase breathers are positioned on

the top of the engine at the front of the engine.
Note: Three breathers need to be cleaned. Use the

same procedure to clean each of the breathers.
10. Repeat Step 1 through Step 9 for each of the
other two breathers.
11. Close the right side access doors (1).
i01325871
Engine Oil Level - Check

SMCS Code: 1000-535-FLV; 1302-535-FLV;
1326-535-OC; 1326-535-FLV; 1348-535-FLV
Illustration 176
g00701519
Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact skin.
1. Open the right side access doors (1).
NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
Note: Clean the area around the dipstick and clean
the area around the oil fill cap before you remove
these components.
Illustration 177
g00701522
2. Loosen outlet hose clamp (2) on the engine

crankcase breather (3). Remove the outlet hose
from engine crankcase breather (3).
3. Loosen clamp (4). Remove engine crankcase
breather (3).
4. Check the condition of the seal on engine
crankcase breather (3). If the seal is damaged,
replace engine crankcase breather (3).
5. Wash engine crankcase breather (3) in clean
6. Shake engine crankcase breather (3) or use
pressure air to dry engine crankcase breather (3).
Illustration 178
g00701412
1. Open left side engine compartment access door

(1).
114
Maintenance Section
Engine Oil Sample - Obtain
Illustration 179
SEBU6907-09
g00701618
Illustration 181
g00713862
Illustration 182
g00696017
2. Before you start the engine, check the ENGINE

STOPPED side of dipstick (2) while the engine is
stopped. Maintain the oil level between the ADD
mark and the FULL mark.
Start the engine and check the ENGINE
RUNNING side of dipstick (2) while the engine is
running. Maintain the oil level between the ADD
mark and the FULL mark.
Sampling valve (2) is located on the oil filter base.

The oil filter base is located behind access door (1)
on the right side of the machine.
Illustration 180
g00723833
3. Remove oil filler cap (3). If necessary, add oil.

4. Clean oil filler cap (3) and install oil filler cap (3).
5. Close engine compartment access door (1).
i01863853
Refer to Special Publication, SEBU6250, SOS Oil

Analysis for information that pertains to obtaining
a sample of the hydraulic oil. Refer to Special
Publication, PEHP6001, How To Take A Good Oil
Sample for more information about obtaining a
sample of the hydraulic oil.
i01863855
Engine Oil and Filter - Change

SMCS Code: 1302-044-OC; 1308-510; 1318-510;
1326-535-OC; 1348-044
Engine Oil Sample - Obtain

SMCS Code: 1348-008; 1348-554-SM; 7542-008;
7542-554-OC, SM

contact the skin.

contact skin.
NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
SEBU6907-09
115
Maintenance Section
Engine Oil and Filter - Change
1. Park the machine on a level surface and engage

the parking brake. Stop the engine.
Note: Drain the crankcase while the oil is warm. This
allows waste particles that are suspended in the oil to
drain. As the oil cools, the waste particles will settle
to the bottom of the crankcase. The particles will not
be removed by draining the oil and the particles will
recirculate in the engine lubrication system with the
new oil.
Note: Articulate the machine to the left in order to get
better access to the crankcase drain valve.
Illustration 184
g00703067
3. Remove the oil pan drain plug.

4. Open crankcase drain valve (2). Allow the oil to
drain into a suitable container.
Note: Discard any drained fluids and discard any
filter elements according to local regulations.
5. Close drain valve (2).
Illustration 183
g00713862
2. Open access door (1) on the right side of the

machine.
NOTICE
products.
6. Clean the area around engine oil filters (3) before

you remove the engine oil filters (3). Remove
engine oil filters (3) with a strap type wrench. See
Operation and Maintenance Manual, Oil Filter Inspect.
7. Clean the base of the engine oil filter housing.
Make sure that all of the old filter gasket is
removed.
8. Apply a light coat of engine oil to the gasket of the
new engine oil filter.
9. Install the new engine oil filter by hand. Additionally
tighten the engine oil filter by 3/4 of a turn, after
the gasket contacts the filter base.

mandates.
Illustration 185
g00713946
10. Open access door (4) on the left side of the

machine.
116
Maintenance Section
Engine Overheating
SEBU6907-09
15. Stop the engine. Close access door (4). Close

access door (1.)
i01485299
Engine Overheating
SMCS Code: 1000; 1350; 1353
If your machine experiences an engine overheating
problem, do the following maintenance procedures
in the order that is listed:
Illustration 186
g00701617
1. Operation and Maintenance Manual, Cooling

System Level Check
2. Operation and Maintenance Manual, Radiator Clean
3. Operation and Maintenance Manual, Belts Inspect/Adjust/Replace
System Pressure Cap - Clean/Replace
5. Operation and Maintenance Manual, Radiator
Core - Clean
Illustration 187
g00703089
11. Clean the area around the dipstick before you

remove dipstick (6). Clean the area around the
oil filler cap before you remove oil filler cap (5).
Remove the oil filler cap (5). Fill the crankcase
with new oil. See Operation and Maintenance
Manual, Capacities (Refill). Clean filler cap (5)
and install filler cap (5).

System Water Temperature Regulator - Replace
If the engine overheating problem is not corrected,
i00357039
Engine Power Loss

SMCS Code: 1000; 1051; 1250
Note: If equipped, the Wiggins fluid service system

can be used in order to quickly drain the engine
crankcase. The port for engine oil is located on the
control box for the Wiggins fluid service system. The
control box is located on the left rear of the engine
enclosure.
If your machine experiences an engine power loss,

do the following maintenance procedures in the order
listed:
12. While the engine is stopped, check the SAFE

STARTING RANGE side of dipstick (6). Maintain
the oil level within the gauge lines. If necessary,
add oil.
1. Engine Air Filter Service Indicator - Inspect
13. Start the engine and allow the oil to warm. Check
the engine for leaks.
14. Run the engine. Check the SAFE OPERATING
RANGE side of dipstick (6) while the engine is
running. Maintain the oil level within the gauge
lines. If necessary, add oil .
See Operation and Maintenance Manual for the

following topics:
2. Engine Air Precleaner - Clean

3. Engine Air Filter Primary Element - Clean/Replace
4. Engine Air Filter Secondary Element - Replace
5. Fuel Tank Water and Sediment - Drain
6. Fuel Tank Cap and Strainer - Clean
7. Fuel System Primary Filter - Clean/Inspect/
Replace
SEBU6907-09
117
Maintenance Section
Engine Valve Lash - Check
8. Fuel System Secondary Filter - Replace
i00128925
If the engine power loss problem is not corrected,

Engine Valve Rotators - Inspect

SMCS Code: 1109-040
i01498587
Engine Valve Lash - Check

SMCS Code: 1105-535
When inspecting the valve rotators, protective

glasses or face shield and protective clothing
must be worn, to prevent being burned by hot oil
spray.
Ensure that the engine can not be started while

this maintenance is being performed. To help prevent possible injury, do not use the starting motor
to turn the flywheel.
Inspect the engine valve rotators after the valve

clearances have been set.
Hot engine components can cause burns. Allow

additional time for the engine to cool before measuring/adjusting valve lash clearance.
2. Watch the top surface of each valve rotator. When

the intake valve or the exhaust valve closes, the
engine valve rotator should turn slightly.
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjustment procedure.
Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This reduced efficiency could result in excessive fuel usage
and/or shortened engine component life.
NOTICE
Do not use the yoke that comes out of the front of the
engine in order to turn over the engine. Damage to the
crankshaft vibration damper can occur.
1. Start the engine and run the engine at low idle.
If an intake valve or an exhaust valve fails to rotate,

consult your Caterpillar Dealer.
i01328576
Ether Starting Aid Cylinder Replace

SMCS Code: 1456-510-CD
The ether starting aid cylinder is mounted on the left
side of the engine compartment.
The adjustment is necessary due to the initial wear of

the valve train components and to the seating of the
valve train components.
This maintenance is recommended by Caterpillar
as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.
Ensure that the engine is stopped before you
measure the valve lash. To obtain an accurate
measurement, allow the valves to cool before you
perform this maintenance.
Remove the cover in order to access the rear of
the engine. Check the valve lash. For the correct
adjustment procedure, refer to Systems Operation,
Testing and Adjusting, Engine Valve Lash Inspect/Adjust.
Illustration 188
g00714280
1. Open engine compartment access door (1).
118
Maintenance Section
Evaporator Coil and Heater Coil - Clean
Illustration 189
SEBU6907-09
g00702997
2. Loosen ether cylinder retaining clamp (2).

Unscrew the ether cylinder.
3. Remove the used gasket. Install the new gasket.
A new gasket is provided with each new ether
cylinder.
4. Install the new ether cylinder. Tighten the ether
cylinder hand tight. Tighten clamp (2) with your
fingers.
i01827363
Evaporator Coil and Heater

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.
2. Remove both of the covers.
Illustration 190
g00931904
3. Clean evaporator coil (1) and clean heater coil (2).

Replace both coils.
4. Replace both of the covers and replace the seat.
Note: If you are operating the machine under harsh
conditions or with the cab door open, it may be
necessary to clean the coils more often.
i01353750
Fan Drive Bearing and Belt

Tightener - Lubricate
SMCS Code: 1358-086-BD; 1358-086; 1359-086;
1359-086-BD
Wipe the fittings before you apply lubricant to the
fittings.
Illustration 191
g00714493
SEBU6907-09
119
Maintenance Section
Final Drive Lip Seal - Replace
The fittings for the fan drive bearing and the belt
tightener are located on the left, rear of the machine.
The fittings are located near the oil filler tube.
Lubricate fitting (1) in order to lubricate the fan drive
bearing. Lubricate fitting (2) in order to lubricate the
belt tightener.
i01769015
Final Drive Lip Seal - Replace
i01860307
Fuel System - Fill

SMCS Code: 1250-544
Personal injury or death may result from failure to

adhere to the following procedures.
SMCS Code: 4050-510-SA
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.
1. Use a high pressure sprayer to clean the area

of tandem housing that is located between the
tandem and the machine.
Clean up all leaked or spilled fuel. Do not smoke

while working on the fuel system.
Turn the disconnect switch OFF or disconnect the
battery when changing fuel filters.
NOTICE
during performance of inspection, maintenance, testing, adjusting, and repair of the machine. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any component containing fluids.
mandates.
Illustration 192
g00808649
2. Remove the 24 bolts (1) that secure the

three-piece retainer (2) to the housing.
Reference: See Operation and Maintenance Manual,

Capacities (Refill) for the capacity of the fuel tank
for your machine.
3. Remove the three-piece retainer and the existing

seal. Discard the seal.
4. Install the new seal.
5. Install the three-piece retainer and 24 bolts.
Illustration 193
g00948363
1. Clean filler cap (1) and the surrounding area.

2. Remove filler cap (1).
3. Fill fuel tank (2) with fuel.
4. Install filler cap (1).
120
Maintenance Section
Fuel System - Prime
SEBU6907-09
Note: Prime the fuel system. See Operation and

Maintenance Manual, Fuel System - Prime for more
information.
i01330090
Fuel System - Prime

SMCS Code: 1250-548; 1258-548
Turn the disconnect switch OFF when draining
and/or removing any fuel system components.
The priming pump for the fuel system is positioned
in the engine compartment at the right rear of the
machine.
Illustration 196
g00702996
3. Open engine access door (3) on the left side of

the machine.
NOTICE
products.
mandates.
Illustration 194
g00713997
1. Open engine access door (1) on the right side of

the machine.
Illustration 197
g00703832
4. Open drain (5) on the water separator bowl.
Illustration 195
g00714002
2. Check that fuel supply valves (2) are open. The

fuel supply valves are positioned in the engine
compartment on the right side of the engine. Close
engine access door (1).
5. Unlock priming pump plunger (4) by turning

priming pump plunger (4) counterclockwise. Pull
out priming pump plunger (4).
6. Operate priming pump plunger (4) until fuel that is
free of air bubbles flows out of drain (5). Allow the
fuel to flow into a suitable container.
SEBU6907-09
121
Maintenance Section
Fuel System Water Separator Element - Replace
Note: Discard any drained fluids according to local

regulations.
7. Lock priming pump plunger (4) by turning priming
pump plunger (4) clockwise.
8. Close drain (5).
9. Start the engine. Look for leaks around the primary
fuel filter and the secondary fuel filter.
10. Close engine access door (3).
i01866340
Fuel System Water Separator

Element - Replace
Illustration 199
g00714002
1. Open access door (1) on the right side of the

machine. Close the fuel supply valves (2).
SMCS Code: 1263-510-FQ
NOTICE
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
system parts.
Illustration 200
g00702996
2. Open access door (3) on the left side of the

machine.
NOTICE
Illustration 198
g00713997

products.
mandates.
122
Maintenance Section
Fuel System Secondary Filter - Replace
SEBU6907-09
i01769106
Fuel System Secondary Filter Replace

SMCS Code: 1261-510-SE
Illustration 201
g00703611
3. In order to drain the primary filter, open drain

valve (6) on water separator bowl (5). The water
separator bowl is under water separator element
(4). Catch the fuel in a suitable container.
regulations.
4. Remove water separator element (4) and water
separator bowl (5).

NOTICE
Do not fill the fuel filters with fuel before installing the
fuel filters. The fuel will not be filtered and could be
contaminated. Contaminated fuel will cause accelerated wear to fuel system parts.
The secondary filters for the fuel system are
positioned in the engine compartment at the left rear
of the machine.
5. Remove water separator bowl (5) from water

separator element (4).
6. Wash water separator bowl (5) in a clean
nonflammable solvent. Use pressure air to dry
water separator bowl (5).
7. Install the clean water separator bowl onto a new
water separator element.
8. Clean the filter housing base.
9. Coat the seal of the new water separator element
with clean diesel fuel.
Illustration 202
g00713997
Illustration 203
g00714002
10. Install the water separator element onto the filter

housing.
11. Open the fuel supply valves (2).
13. Prime the fuel system. See the Operation and
Maintenance Manual, Fuel System - Prime for
more information.

the machine. Close the fuel supply valves (2).
SEBU6907-09
123
Maintenance Section
Fuel Tank Cap and Strainer - Clean
5. Clean the mounting base for secondary fuel filter

(4). Make sure that you remove all of the old seal.
6. Coat the seal of a new secondary fuel filter with
clean diesel fuel.
7. Install the new secondary fuel filter by hand.
Tighten the new secondary fuel filter until the seal
contacts the mounting base. Then tighten the new
secondary fuel filter by an additional full turn (360
degrees).
Illustration 204
g00702996
2. Open engine access door (3) on the left side of

the machine.
NOTICE
products.
mandates.
Illustration 205
Use the rotation index marks on the new

secondary fuel filter as a guide for tightening the
filter. These rotation index marks are spaced at
intervals of 1/4 turn.
8. Open the fuel supply valves (2).
10. Prime the fuel system. See the Operation and
Maintenance Manual, Fuel System - Prime for
more information.
i01863857
Fuel Tank Cap and Strainer Clean

SMCS Code: 1273-070-STR; 1273-070-Z2
The fuel tank cap is positioned on the top left side
of the machine.
g00703641
3. Remove secondary fuel filters (4).
Illustration 206
g00950226
4. Drain the fuel from secondary fuel filters (4) into a

suitable container.
1. Remove fuel tank cap (1) and disassemble fuel

tank cap (1).

regulations.
2. Inspect the seal on fuel tank cap (1) for damage. If

the seal is damaged, replace the seal.
3. Remove the strainer from the filler opening.
124
Maintenance Section
Fuel Tank Water and Sediment - Drain
SEBU6907-09
4. Wash the strainer and fuel tank cap (1) in clean

5. Disassemble vent assembly (2). Wash vent
assembly (2) in clean nonflammable solvent.
i01692877
Fuses - Replace
SMCS Code: 1417-510
6. Inspect vent assembly (2) for damage.

7. Reassemble vent assembly (2). If vent assembly
(2) is damaged, replace the vent assembly.
8. Apply a light coat of oil to vent assembly (2). Install
vent assembly (2).
9. Assemble fuel tank cap (1).
10. Install the strainer.
11. Install fuel tank cap (1).
Illustration 208
i01330271
Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543-M&S
g00703986
The fuses are located behind the fuse panel.
Fuses Fuses protect the electrical system from

damage that is caused by overloaded circuits.
Replace the fuse if the element is separated. Check
the circuit if the element is separated in a new fuse.
Repair the circuit.
NOTICE
Always replace fuses with the same type and capacity
fuse that was removed. Otherwise, electrical damage
could result.
NOTICE
If it is necessary to replace fuses frequently, an electrical problem may exist.
Contact your Caterpillar dealer.
Illustration 207
g00703959
Drain plug (1) is located at the left side of the machine

under the fuel tank.
The fuse panel is located in the base of the steering

column. Several other fuses are located at the
operators right side.
1. Remove drain plug (1) and allow the water and

sediment to drain into a suitable container.
regulations.
2. Install drain plug (1).
Illustration 209
g00703980
SEBU6907-09
125
Maintenance Section
Fuses - Replace
Flood Lights (Blade) (1) 10 Amp
Radio (12) 10 Amp
Front Flood Lights (2) 10 Amp
Lighter (13) 10 Amp
Rear Flood Lights (3) 10 Amp
Converter (14) 15 Amp
Flood Lights (Ripper) (4) 10 Amp
Horn (15) 10 Amp
Parking Brake (5) 10 Amp
Turn Signals (16) 10 Amp
Electronic Monitoring System (6) 10

Amp
Spare (17)
Blade Cushion (7) 10 Amp
Seat (8) 15 Amp
Air Conditioning (9) 15 Amp
Illustration 211
g00704012
Front Wiper and Washer (18) 15 Amp
Rear Wiper and Washer (19) 10 Amp
Radio and Converter (20) 15 Amp
Illustration 210
g00703984
Key Start Switch (10) 10 Amp

Spare (21)
Tail Lights (11) 10 Amp
126
Maintenance Section
Hydraulic System Oil - Change
SEBU6907-09
Rotating Beacon and Dome Lamp (22)

10 Amp
Fan (23) 10 Amp
Illustration 212
g00871597
i01902063
Hydraulic System Oil - Change

SMCS Code: 5050-044; 5056-044; 5095-044
At operating temperature, the hydraulic oil tank is

hot and under pressure.
Note: If the hydraulic oil is not being monitored

by the Caterpillar SOS Oil Analysis program or
an equivalent oil sampling program, change the
hydraulic oil at every 2000 service hour interval.
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact
skin.
Before installation or removal of any hydraulic test
equipment, relieve the pressure in the hydraulic
tank by slowly loosening the filler cap.

contact skin.
1. Slowly remove the hydraulic oil filler cap (1).
Operate the machine until the oil is warm.

Park the machine on a level surface with the 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 link. The frame lock link
must move freely in the frame. Move the front wheels
to vertical. Install the wheel lean locking bolt. Engage
the parking brake. Stop the engine.
The hydraulic system oil tank is positioned behind
the operator station at the center of the machine.
Illustration 213
g00871604
SEBU6907-09
127
Maintenance Section
Hydraulic System Oil Filter - Replace
i01693063
NOTICE
products.
mandates.
2. The drain plug (3) is positioned in the bottom of
the hydraulic oil tank. Remove drain plug (3).
Drain the oil into a suitable container.
3. Replace the filter for the hydraulic system oil. See
Operation and Maintenance Manual, Hydraulic
System Oil Filter - Replace.
4. 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.
Hydraulic System Oil Filter Replace

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

contact skin.
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 link. The frame lock link must move
freely in the frame. Move the front wheels to vertical
and install the wheel lean locking bolt. Engage the
parking brake. Stop the engine.
Clean the area around the filler cap before removing
the filler cap. Clean the area around the filter cover
before you remove the filter cover.
5. Clean drain plug (3) and install drain plug (3).

6. Install the filler screen.
7. Fill the hydraulic system oil tank. See Operation
and Maintenance Manual, Capacities (Refill).
8. Inspect the filler cap gasket. If the filler cap gasket
is damaged, replace the filler cap gasket.
9. Install oil filler cap (1).
Illustration 214
g00704189
10. Start the engine. Run the engine for a few

minutes.
11. Maintain the oil level above the ADD mark in
sight gauge (2). If necessary, add oil through the
filler tube (1).
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.
13. If necessary, tighten any loose clamps and any
loose connections. Replace any damaged hoses.

skin.
1. Slowly remove hydraulic oil filler cap (2) in order
to relieve the tank pressure.
128
Maintenance Section
Hydraulic System Oil Level - Check
SEBU6907-09
2. Remove filter cover (1) from the hydraulic system

oil tank.
3. Inspect the seal for the cover (1). If necessary,
replace the seal.
NOTICE
products.
mandates.
4. Remove the filter element and discard the filter
element.
regulations.
5. Install a new filter element.
i01693038
Hydraulic System Oil Level Check

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

contact skin.
Operate the machine until the oil is warm.
Park the machine on a level surface with the 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 link. The frame lock link
must move freely in the frame. Move the front wheels
to vertical and install the wheel lean locking bolt.
Engage the parking brake. Stop the engine.
The hydraulic oil tank is located behind the operator
station at the center of the machine. The hydraulic
tank sight gauge is positioned on the left side of the
oil tank.
6. Install cover (1).
Illustration 216
Illustration 215
g00704076
7. Maintain the hydraulic oil level to the FULL mark

on sight gauge (3).
8. Inspect the filler cap gasket. If the filler cap gasket
is damaged, replace the filler cap gasket. Install
the oil filler cap (2).
g00871597
1. Maintain the oil level to the FULL mark on

hydraulic tank sight gauge (2).
SEBU6907-09
129
Maintenance Section
Hydraulic System Oil Sample - Obtain
i01353883

Kingpin Bearings - Lubricate

SMCS Code: 4314-086
skin.
The kingpin bearings are located on the inside of the

front wheels.


for the kingpin bearings. If a remote line becomes
and lubricate the bearings at the fitting until the line
can be replaced.
2. If necessary, add oil. Slowly loosen the filler cap in

order to relieve the tank pressure. Remove filler
cap (1). Add oil through the filler tube.

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

i01863865
Hydraulic System Oil Sample

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

contact the skin.
Illustration 217
Illustration 218
g00714555
The lubrication fittings for the right side kingpin are

located in the bank of fittings that is on the front,
right side of the machine. Lubricate fitting (1) in order
to lubricate the upper kingpin bearing on the right
side of the machine. Lubricate fitting (2) in order to
lubricate the lower kingpin bearing that is on the right
g00696019
Sampling valve (1) is located underneath the

hydraulic tank.
Illustration 219
g00714556
Lubricate fitting (3) in order to lubricate the upper

kingpin bearing that is on the left side of the machine.
Lubricate fitting (4) in order to lubricate the lower
kingpin bearing that is on the left side of the machine.
130
Maintenance Section
Machine Structure - Inspect
SEBU6907-09
i01353982
Machine Structure - Inspect

SMCS Code: 3260-040; 5207-040; 6170-040;
7050-040
Inspect the machine for cracks in each of the
indicated locations.
Illustration 222
g00714620
Front Frame (Detail B)
Illustration 220
g00714617
Front Frame
Illustration 223
g00714621
Rear Frame
Illustration 221
Front Frame (Detail A)
g00714619
Illustration 224
Top View of Circle
g00714622
SEBU6907-09
131
Maintenance Section
Moldboard Wear Strip - Inspect/Adjust/Replace
i01331857
Moldboard Wear Strip Inspect/Adjust/Replace

SMCS Code: 6174-025; 6174-040; 6174-510
1. Rotate the blade. Position the blade at an angle of
90 degrees to the frame. Lower the blade to the
ground. Stop the engine.
Illustration 225
g00714623
Bottom View of Circle
Illustration 228
g00704742
2. Remove the top retaining plates (1) and the

bottom retaining plates (2). Visually inspect the
wear strips. If the wear strips are worn close to the
moldboard, replace the wear strips.
Illustration 226
g00714625
Top View of Front Axle
Illustration 229
g00704746
(3) Wear strip (top)

Illustration 227
Drawbar
g00714626
3. When wear strip (3) is installed, the longer end of

wear strip (3) should be installed in the position
that is shown in illustration 229.
132
Maintenance Section
Oil Filter - Inspect
SEBU6907-09
i02106227
Oil Filter - Inspect

SMCS Code: 1308-507; 3004-507; 3067-507;
5068-507
Inspect a Used Filter for Debris
Illustration 230
g00721510
(4) Wear strip (bottom)
4. When wear strip (4) is installed, the longer end of

wear strip (4) should be installed in the position
that is shown in illustration 230.
5. Install shims between the moldboard rail and the
wear strips at the location of minimum clearance.
Add shims in order to provide a clearance of
0.13 mm to 0.89 mm (.005 inch to .035 inch).
Note: The shims that are required should be divided
evenly between the upper wear strips and the lower
wear strips.
6. Install top retaining plates (1) and install bottom
retaining plates (2).
7. Start the engine. Raise the blade so that the blade
will not contact the ground. Sideshift the blade
through the entire limit of travel. Measure the
clearance between the wear strips and the blade.
This will allow you to determine the location of the
minimum clearance.
8. Stop the engine.
Illustration 231
g00100013
The element is shown with debris.
Use a filter cutter to cut the filter element open.

Spread apart the pleats and inspect the element for
metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
failure.
If metals are found in the filter element, a magnet can
be used to differentiate between ferrous metals and
nonferrous metals.
Ferrous metals can indicate wear on steel parts and
on cast iron parts.
Nonferrous metals can indicate wear on the
aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.
Small amounts of debris may be found in the filter
element. This could be caused by friction and by
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount
of debris is found.
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.
SEBU6907-09
133
Maintenance Section
Radiator - Clean
i01354187
i01860283
Radiator - Clean
Refrigerant Dryer - Replace
SMCS Code: 1353-070; 1805-070; 1810-070
SMCS Code: 7322-510
Personal injury can result from contact with refrigerant.

Contact with refrigerant can cause frost bite. Keep
face and hands away to help prevent injury.
Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.
Illustration 232
g00714817
1. Remove the access cover (1) on the left rear of

the machine. Remove the access cover on the
right rear of the machine.
2. Remove any dirt from the area around the radiator.
Remove any debris from the area around the
radiator.
3. Install the access covers.
i01671005
Radiator Core - Clean

SMCS Code: 1353-070; 1353-070-KO
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.
Always use precaution when a fitting is removed.

Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated
area.
Personal injury or death can result from inhaling
refrigerant through a lit cigarette.
Inhaling air conditioner refrigerant gas through a
lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or
death.
Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.
See Special Publication, SEBD0518, Know Your

Cooling System for the complete procedure for
cleaning the radiator core.
Illustration 233
g00711521
In-line refrigerant dryer (1) is located underneath the

cab on the left side of the machine.
Refer to Service Manual, SENR5664, In-Line
Refrigerant Dryer - Remove and Install for the
replacement procedure of the in-line refrigerant dryer.
134
Maintenance Section
Ripper Linkage and Cylinder Bearings - Lubricate
Note: When you operate the machine in a climate

with high humidity, replace the in-line refrigerant dryer
after every 1000 service hours or 6 months.
i01693202
Ripper Linkage and Cylinder

Bearings - Lubricate
SMCS Code: 5352-086-E2; 6313-086-BD
SEBU6907-09
Retainer pin, when struck with force, can fly out

and cause injury to nearby people.
Make sure the area is clear of people when driving
retainer pins.
To avoid injury to your eyes, wear protective
glasses when striking a retainer pin.
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.
Illustration 234
g00871718
The ripper is lubricated at one central location. A

bank of twelve fittings (1) is located on the left side
of the ripper. If any of the remote fittings become
damaged, install fittings and lubricate the component
at the fittings until the line can be replaced.
Wipe all fittings before lubricating.
Lubricate ten fittings. The fitting that is farthest to the
rear of the machine on each bank of six fittings is
unused.
i01563909
Ripper Tip - Inspect/Replace

SMCS Code: 6808-040; 6808-510
Personal injury or death can result from the ripper

falling.
Block the ripper before changing teeth.
Illustration 235
g00110460
2. Drive out the retainer pin from the retainer side

of the ripper tip. Remove the ripper tip and the
retainer.
3. Clean the adapter, the retainer pin, and the
retainer. Install the retainer in the groove.
4. Install the new ripper tip over the retainer.
5. Drive the retainer pin through the retainer, through
the adapter, and through the ripper tip from the
opposite side of the retainer.
6. Repeat Step 2 through Step 5 in order to replace
additional ripper tips.
7. Raise the ripper. Remove the block. Lower the
ripper to the ground.
SEBU6907-09
135
Maintenance Section
Rollover Protective Structure (ROPS) - Inspect
i01336682
i02429589
Rollover Protective Structure

(ROPS) - Inspect
Seat Belt - Inspect
SMCS Code: 7323-040; 7325-040
Always check the condition of the seat belt and the

condition of the seat belt mounting hardware before
you operate the machine. Replace any parts that are
damaged or worn before you operate the machine.
NOTICE
Do not attempt to straighten the ROPS structure. Do
not repair the ROPS by welding reinforcement plates
to the structure.
SMCS Code: 7327-040
If there are any cracks in the welds, in the castings, or

in any metal section of the ROPS, consult your Caterpillar dealer for repairs.
Illustration 237
g00932801
Typical example
Illustration 236
g00715401
1. There are four retaining pins (1) for the ROPS.

Two retaining pins are located on each side of the
cab. Each retaining pin (1) is held in place with
a smaller pin (2).
2. Inspect all the pins. Replace any damaged pins
or any missing pins with only original equipment
parts.
3. Inspect the ROPS for any loose bolts or any
damaged bolts. Replace any damaged bolts or
any missing bolts with only the original equipment
parts.
Note: Apply oil to all ROPS bolt threads before you
install the bolts for the ROPS. Failure to apply oil can
result in improper bolt torque.
4. When you operate the machine on a rough
surface, the ROPS may rattle or the ROPS may
make a noise. If the ROPS rattles or if the ROPS
makes a noise, replace the ROPS mounting
supports.
Check the seat belt mounting hardware (1) for wear

or for damage. Replace any mounting hardware that
is worn or damaged. Make sure that the mounting
bolts are tight.
Check buckle (2) for wear or for damage. If the buckle
is worn or damaged, replace the seat belt.
Inspect the seat belt (3) for webbing that is worn or
frayed. Replace the seat belt if the seat belt is worn
or frayed.
Consult your Caterpillar dealer for the replacement of
the seat belt and the mounting hardware.
Note: Within three years of the date of installation or
within five years of the date of manufacture, replace
the seat belt. Replace the seat belt at the date which
occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.
If your machine is equipped with a seat belt
extension, also perform this inspection procedure for
the seat belt extension.
136
Maintenance Section
Seat Belt - Replace
SEBU6907-09
i02429594
Seat Belt - Replace
i02601320
Steering Accumulator - Check

(If Equipped)
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.
SMCS Code: 4331-535
Illustration 239
g00707900
The steering accumulator is located on the right side of the frame

under the engine compartment.
Illustration 238
(1) Date
(2) Date
(3) Date
(4) Date
g01152685
of installation (retractor)
of installation (buckle)
of manufacture (tag) (fully extended web)
of manufacture (underside) (buckle)
Consult your Caterpillar dealer for the replacement of

the seat belt and the mounting hardware.
If your machine is equipped with a seat belt
extension, also perform this replacement procedure
for the seat belt extension.
Steer the machine to the left and steer the machine

to the right. If the movement of the steering system
is abnormal, check the nitrogen precharge. Operate
the hydraulic equipment. If the movement of the
steering is abnormal, check the nitrogen precharge. If
necessary, add nitrogen. Refer to Systems Operation,
Testing and Adjusting, SENR1429, Accumulator
(Steering) - Test and Charge for the following
information: the correct checking procedure, the
correct filling procedure, and the recommended
pressure. Your Caterpillar dealer has the appropriate
tools for measuring the precharge pressure of the
steering accumulator. Only use dry nitrogen gas to
recharge the steering accumulator.
i01355081
Steering Cylinder Ends Lubricate

SMCS Code: 4303-086
for the steering cylinders. If a remote line becomes
and lubricate the steering cylinder at the fitting until
the remote line can be replaced.
SEBU6907-09
Illustration 240
137
Maintenance Section
Steering Linkage - Lubricate
g00715308
Illustration 242
g00715283
The fittings for the steering cylinder (right side) are on the right
The fittings for the steering linkage (right side) are on the right
Lubricate fitting (1) in order to lubricate the rod end of

the steering cylinder on the right side of the machine.
Lubricate fitting (2) in order to lubricate the head
end of the steering cylinder on the right side of the
machine.
Lubricate fitting (1) in order to lubricate the steering

linkage at the right side of the machine.
Illustration 243
Illustration 241
g00715309
The fittings for the steering cylinder (left side) are on the left side
of the machine.
Lubricate fitting (3) in order to lubricate the rod end of

the steering cylinder on the left side of the machine.
Lubricate fitting (4) in order to lubricate the head end
of the steering cylinder on the left side of the machine.
i01355013
Steering Linkage - Lubricate

SMCS Code: 4318-086
for the steering linkage. If a remote line becomes
and lubricate the steering linkage at the fitting until
the line can be replaced.
g00715285
The fittings for the steering linkage (left side) are on the left side
of the machine.
Lubricate fitting (2) in order to lubricate the steering

linkage at the left side of the machine.
138
Maintenance Section
Tandem Breather - Clean/Replace
SEBU6907-09
i01693639
Tandem Breather Clean/Replace
i01693504
Tandem Drive Oil - Change

SMCS Code: 4071-510
SMCS Code: 4062-070-BRE; 4062-510-BRE
Illustration 245
g00708046
The tandem drive housings are located between the rear wheels
on each side of the machine.
Illustration 246
Illustration 244
g00871840
1. Remove breathers (1) from both tandems.

2. Wash breathers (1) in clean, nonflammable
solvent.
3. Use pressure air to dry breathers (1).
4. Install breathers (1) in both tandems.
Note: Replace breathers (1) if the breathers are
damaged.
g00714115
NOTICE
products.
mandates.
1. Remove drain plug (3) from the bottom of tandem
drive housing (1). Allow the oil to drain into a
suitable container.
SEBU6907-09
139
Maintenance Section
Tandem Drive Oil Level - Check
Note: The Wiggins fluid service system can be used

to drain the tandem housings. The Wiggins fluid
service system can also be used to fill the tandem
housings.
2. Fill the tandem drive housing with oil. See
Operations and Maintenance Manual, Lubricant
Viscosities. Also see Operations and Maintenance
Manual, Capacities (Refill).
4. Start the engine and operate the machine for a
few minutes. Check for leaks.
Illustration 249
g00714115
1. Remove cover (2).
Illustration 247
g00708047
5. Stop the engine. Remove cover (2). Check the oil

level in sight glass (4). Add oil, if necessary. Sight
glass (4) must be full. Do not overfill the tandem
drive housing.
6. Repeat Step 1 through Step 5 for the other tandem
drive housing.
i01693590
Tandem Drive Oil Level - Check

SMCS Code: 4071-535
Illustration 250
g00708047
2. Check the oil in sight glass (4). Add oil, if

necessary. Oil can be added through drain plug
(3).
Note: The Wiggins fluid service system can be used
to drain the tandem housings. The Wiggins fluid
service system can also be used to fill the tandem
housings.
3. Remove drain plug (3). See Operations and
Maintenance Manual, Lubricant Viscosities.
Also see Operations and Maintenance Manual,
Capacities (Refill).
4. Add oil. Sight glass (4) must be full. Do not overfill
tandem drive housing (1). Replace drain plug (3).
5. Repeat Step 1 through Step 4 for the other tandem
drive housing.
Illustration 248
g00708046
The tandem drive housings are located between the rear wheels
on each side of the machine.
140
Maintenance Section
Tandem Drive Oil Sample - Obtain
SEBU6907-09
i01863867
Tandem Drive Oil Sample Obtain

SMCS Code: 4071-008
Operation and Maintenance Manual, Tire Inflation

with Nitrogen
Operation and Maintenance Manual, Tire Shipping

Pressure
Operation and Maintenance Manual, Tire Inflation

Pressure Adjustment
Operation and Maintenance Manual, Tire

Information
i01693614
Transmission and Differential

Oil - Change
SMCS Code: 3080-510; 3258-510-OC
Illustration 251
g00696018
The oil sump is located behind the access door near

the top of the tandem housing.
Clean the area around the differential drain plug

before the differential drain plug is removed. Clean
the area around the drain plug of the transmission
case before the drain plug is removed. Clean the area
around the dipstick before the dipstick is removed.
Clean the area around the filler cap before the filler
cap is removed.

contact skin.
i01863872
Tire Inflation - Check
NOTICE
SMCS Code: 4203-535-AI; 4203-535-PX

products.
mandates.
Illustration 252
g00103147
Measure the pressure on each tire. Consult your tire

dealer for the correct load rating and for the correct
operating pressures.
If necessary, inflate the tires. Refer to the following
additional information about tire inflation:
Operate the engine until the transmission oil is warm

and the differential oil is warm. Park the machine on
a level surface and engage the parking brake. Lower
the blade and apply slight downward pressure to the
blade. Stop the engine.
SEBU6907-09
141
Maintenance Section
Transmission and Differential Oil - Change
Note: Drain the transmission case while the oil is

warm. Drain the differential case while the oil is warm.
This allows waste particles that are suspended in the
oil to drain. 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.
Illustration 255
g00710169
5. Fill the transmission case with oil through filler

tube (3). See Operation and Maintenance Manual,
Illustration 253
g00710167
Transmission
1. Remove the drain plug (1) for the transmission
case. Drain the oil into a suitable container.
6. Remove transmission breather (5) and discard

transmission breather (5). Install a new
transmission breather.
7. Start the engine and run the engine at low
idle. Inspect the transmission and differential
components for leaks.

regulations.
2. Change the filter element and clean the screens.
See Operation and Maintenance Manual,
Transmission and Differential Oil Filter and
Screen in the Maintenance Interval Schedule.
Illustration 256
g00710272
8. Engage the transmission modulator pedal (6).

Slowly operate the transmission direction and
speed control lever (7) in order to circulate the oil.
9. With the engine at low idle, maintain the oil level
between the marks on dipstick (4). If necessary,
add oil through filler tube (3).
Illustration 254
g00710121

the machine.

142
Maintenance Section
Transmission and Differential Oil Filter and Screens - Replace/Clean
Differential and Bevel Gear
SEBU6907-09
i01693517

Oil Filter and Screens Replace/Clean
SMCS Code: 3030-070-Z3; 3030-510-Z3;
3067-070; 3067-510; 3258-070-FI; 3258-070-Z3;
3258-510-FI; 3258-510-Z3
Illustration 257
g00710181

contact skin.
Note: The oil change interval for the differential can

be extended if the differential oil is monitored with the
Scheduled Oil Sampling program.
1. Remove differential drain plug (10). Drain the oil
into a suitable container.
regulations.
3. Remove differential filler plug (9). Fill the
differential to the bottom of the filler plug opening.
See Operations and Maintenance Manual,
Lubricant Viscosities. See Operations and
Maintenance Manual, Capacities (Refill).
4. Clean filler plug (9) and install filler plug (9).
Illustration 258
g00710341
1. Install frame lock link (1) on the right side of the

machine between the front frame and the rear
frame.
5. Remove differential breather (8) and wash

differential breather (8) in clean, nonflammable
solvent. Install the clean breather.
6. Operate the machine on level ground for a few
minutes.
7. Check for leaks.
8. Recheck the oil level.
9. If necessary, add oil . Install filler plug (9).
Illustration 259
g00710121
2. Open engine compartment access cover (2) on

the left side of the machine.
SEBU6907-09
143
Maintenance Section
Transmission and Differential Oil Filter and Screens - Replace/Clean
12. Slowly remove the cover (5) for the magnetic

screen housing. Allow the oil to drain into a
suitable container.
regulations.
13. Remove the suction screen. Remove the
magnetic screen tube assemblies.
Illustration 260
g00710324
3. Remove drain plug (3) from transmission oil filter

housing (4). Allow the oil to drain into a suitable
container.
regulations. Discard any filter elements according to
local regulations.
4. Remove the oil filter housing (4).
5. Remove the used element and discard the used
element.
6. Clean transmission oil filter housing (4) and drain
plug (3) with a clean, nonflammable solvent.
7. Clean the base of transmission oil filter housing
(4).
8. Insert a new filter element into transmission oil
filter housing (4).
9. Replace the filter housing base seal.
14. Separate the magnets and the tube assembly

from the screen. Wash the screen in clean,
nonflammable solvent and wash the tube
assembly in clean, nonflammable solvent. Allow
the screen to dry and allow the tube assembly to
dry.
NOTICE
Do not drop or rap magnets on hard objects, or damage can result. Replace damaged magnets.
15. Clean the magnets with a cloth or clean the
magnets with a stiff bristle brush. Allow the
magnets to dry.
16. Install the magnets into the screen and install the
tube assembly into the screen.
17. Install the screen.
18. Inspect the cover seals. If the cover seals are
damaged, replace the cover seals.
19. Install the covers and tighten the bolts.
20. Fill the transmission case with oil through the filler
tube. See Operation and Maintenance Manual,
10. Install transmission oil filter housing (4).

11. Install drain plug (3) in transmission oil filter
housing (4).
22. Start the engine.

23. With the parking brake engaged, run the engine
at low idle in order to circulate the transmission oil.
24. Inspect all of the transmission components for
leaks.
Illustration 261
g00710369
144
Maintenance Section
Transmission and Differential Oil Level - Check
SEBU6907-09
2. Maintain the oil level to the bottom of the filler plug

opening.
3. Install differential filler plug (1).
Transmission
Illustration 262
g00710395
25. With the engine at low idle, maintain the oil level
between the marks on dipstick (6). If necessary,
add the oil through filler tube (7).
Illustration 264
27. Remove frame lock link (1) and store frame lock
link (1).
i01693622

Oil Level - Check
g00710121
1. Open the right side engine access door (2).

2. Clean the area around the dipstick before
removing the dipstick. Clean the area around the
filler cap before you remove the filler cap.
3. Start the engine. Run the engine at low idle.
SMCS Code: 3030-535-FLV; 3080-535-FLV;

3258-535-FLV

contact skin.
Differential and Bevel Gear

Illustration 265
g00710123
4. Remove dipstick (3). Maintain the oil between the

LOW mark and the FULL mark on dipstick (3).
Replace dipstick (3).
5. If necessary, remove filler cap (4) and add oil.
6. Clean filler cap (4) and install filler cap (4).
7. Stop the engine.
Illustration 263
1. Remove differential filler plug (1).
g00710116
SEBU6907-09
145
Maintenance Section
Transmission and Differential Oil Sample - Obtain
i01863878
i01829992

Oil Sample - Obtain
Wheel Bearing Oil (Front) Change
SMCS Code: 3006-008; 3030-008; 3080-008;

3258-008; 7542
SMCS Code: 4205-044; 4208-044; 4234-044;

7551-044-WHL
Illustration 266
g00696016
Sampling valve (1) for the differential oil is located on

the differential lock pump. The differential lock pump
is located in the engine compartment.
Illustration 268
g00934106
The front wheel bearings are located on the inner

side of each front wheel. The check/fill plugs (1) are
located on the housings of each front wheel bearing.
Clean the surface around each check/fill plug before
you change the oil.
NOTICE
Illustration 267
g00696020
Sampling valve (2) for the transmission oil is located

on the transmission pump.

products.
mandates.
2. Use a 1U-7683 Suction Gun in order to remove
the oil from the housing for the wheel bearing.
3. Add oil to the housing for the wheel bearing until
the oil level is at the bottom of the opening for
check/fill plug (1).
5. Repeat Step 1 through Step 4 for the other wheel
bearing.
146
Maintenance Section
Wheel Bearing Oil Level (Front) - Check
SEBU6907-09
i01341134
Wheel Bearing Oil Level (Front)

- Check
SMCS Code: 4205-535-FLV; 4208-535-FLV;
4234-535-FLV; 7551-535-FLV
The front wheel bearings are located on the inner
side of each front wheel. The check/fill plugs (1) are
located on the housings of each front wheel bearing.
Clean the surface area around each check/fill plug
before you check the oil level.
Illustration 270
g00714906
The fittings for the wheel lean bar (right side) are on the right side
of the machine.
Lubricate fitting (1) in order to lubricate the wheel

lean bar at the right side of the machine.
Illustration 269
g00709315

2. Maintain the oil level to the bottom of the opening
for check/fill plug (1). If necessary, add oil.
Illustration 271

4. Repeat Step 1 through Step 3 for the other wheel
bearing.
g00714907
The fittings for the wheel lean bar (left side) are on the left side
of the machine.
Lubricate fitting (2) in order to lubricate the wheel

lean bar at the left side of the machine.
i01354364
Wheel Lean Bar Bearings Lubricate

for the wheel lean bar. If a remote line becomes
and lubricate the wheel lean bar at the fitting until
the line can be replaced.
i01354426
Wheel Lean Bearings Lubricate

for the wheel lean arm bearings. If a remote line
remote line and lubricate the wheel lean arm bearings
SEBU6907-09
Illustration 272
147
Maintenance Section
Wheel Lean Cylinder Bearings - Lubricate
g00714930
Illustration 274
g00715238
The fittings for the wheel lean arm bearings (right side) are on
the right side of the machine.
The fittings for the wheel lean cylinder mounting (right side) are on
the right side of the machine.
Lubricate fittings (1), (2), and (3) in order to lubricate

the wheel lean arm bearings for the right side of the
machine.
Lubricate fitting (1) in order to lubricate the rod end

of the wheel lean cylinder on the right side of the
machine. Lubricate fitting (2) in order to lubricate the
head end of the wheel lean cylinder on the right side
of the machine.
Illustration 273
g00714931
The fittings for the wheel lean arm bearings (left side) are on the
left side of the machine.
Lubricate fittings (4), (5), and (6) in order to lubricate

the wheel lean arm bearings for the left side of the
machine.
i01354944
Wheel Lean Cylinder Bearings

- Lubricate
for the wheel lean cylinders. If a remote line becomes
and lubricate the wheel lean cylinder at the fitting
until the line can be replaced.
Illustration 275
g00715240
The fittings for the wheel lean cylinder mounting (left side) are
on the left side of the machine.
Lubricate fitting (3) in order to lubricate the rod end

of the wheel lean cylinder on the left side of the
machine. Lubricate fitting (4) in order to lubricate the
head end of the wheel lean cylinder on the left side
of the machine.
148
Maintenance Section
Window Washer Reservoir - Fill
SEBU6907-09
i01341175
i01694230
Window Washer Reservoir Fill
Window Wiper Inspect/Replace
SMCS Code: 7306-544-KE
SMCS Code: 7305-040; 7305-510
NOTICE
Use Caterpillar nonfreezing window washer solvent
or a commercially available windshield washer fluid
in order to prevent freezing of the windshield washer
system.
Illustration 277
Illustration 276
g00709332
The window washer reservoirs (1) are located on

the front frame of the machine. The reservoirs are
located below the steps to the right side of the
operators compartment.
1. Remove the caps of the window washer reservoirs
(1).
g00872167
Inspect the upper front windshield wiper blade (1).

If the machine is equipped with a wiper for the rear
window, inspect the wiper blade for the rear window
(2). If any of the wiper blades are streaking any of the
windshields, replace the wiper blade. Also, replace
the wiper blade if the wiper blade is streaking the
rear window.
i01494089
Windows - Clean
SMCS Code: 7310-070; 7340-070
2. Fill the window washer reservoirs through the filler

openings.
3. Replace the caps of the window washer reservoirs
(1).
Illustration 278
g00775840
Use commercially available window cleaning

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

Sebu6907-09 M - 24H

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MAINTENANCE INTERVALS

Operation and Maintenance

Maintenance Interval Schedule

Every 10 Service Hours or Daily

Every 50 Service Hours or Weekly

Initial 250 Service Hours

Every 250 Service Hours

Every 250 Service Hours or Monthly

Every 500 Service Hours

Every 6000 Service Hours or 6 Years

Hydraulic System Oil Sample - Obtain ............... 129

Final Drive Lip Seal - Replace ............................. 119

Every 500 Service Hours or 3 Months

Every 1000 Service Hours or 6 Months

Every 2000 Service Hours or 1 Year

Every 2000 Service Hours or 2 Years

Every 3000 Service Hours or 2 Years

Every 3 Years After Date of Installation or

Every 4000 Service Hours

Every 6000 Service Hours or 3 Years

Every 12 000 Service Hours or 6 Years

Articulation Bearings Lubricate

Apply lubricant through fitting (2) in order to

SMCS Code: 7057-086-BD

The upper articulation bearing has one fitting. Apply

The lubrication fittings for the rod end of the

Articulation Cylinder Bearings

Axle Oscillation Bearings Lubricate

Note: Make sure that any pressure in the lubrication

Lubricate fitting (1) in order to lubricate the front axle

Backup Alarm - Test

If any of the remote lines become damaged, install a

Apply the service brake. Move the transmission

See Service Manual, SENR4724, Automatic

The backup alarm should sound immediately.

The backup alarm is located at the rear of the

Maintain the level of the distilled water to the

bottom of the filler openings. If distilled water is

A battery should not require more than 30 cc

Always recycle a battery. Never discard a battery.

(1 ounce) of water per cell per week. This

In extreme temperatures, check the water in the

6. Close the battery access cover.

Battery Electrolyte Level Check

SMCS Code: 1401-510; 1402-510

The Chart for the Battery Electrolyte

Battery or Battery Cable Inspect/Replace

Tighten the battery retainers on all of the batteries.

2. Turn the key for the battery disconnect switch to

Check the following areas at a minimum interval

5. Disconnect the positive battery cable from the

1. The battery access cover is positioned on top of

6. Inspect the battery terminals for corrosion. Inspect

2. Clean the battery surface with a clean cloth.

7. If necessary, make repairs. If necessary, replace

3. Maintain clean battery terminals. You may use

8. Connect the positive battery cable at the battery.

4. Coat the terminals with corrosion protection. Then,

10. Connect the battery cable at the battery

5. For conventional batteries and low maintenance

11. Install the key for the battery disconnect switch.

Inspect the battery electrolyte level in each

battery cell. A maintenance free battery does