Safety CAT Intervalos de Mantenimientos

MAINTENANCE INTERVALS
Operation and Maintenance

Manual Excerpt
2010 Caterpillar
All Rights Reserved
SEBU7925-08
July 2008
Operation and
Maintenance
Manual
D6R Series III Track-Type Tractor
GJB1-Up (Machine)
WCB1-Up (Machine)
HDC1-Up (Machine)
RFC1-Up (Machine)
TBC1-Up (Machine)
HCD1-Up (Machine)
HKE1-Up (Machine)
WRG1-Up (Machine)
MTJ1-Up (Machine)
DMK1-Up (Machine)
JEK1-Up (Machine)
EXL1-Up (Machine)
JDL1-Up (Machine)
DLM1-Up (Machine)
LFM1-Up (Machine)
LGP1-Up (Machine)
DPS1-Up (Machine)
GMT1-Up (Machine)
MRT1-Up (Machine)
EXW1-Up (Machine)
SAFETY.CAT.COM
92
Maintenance Section
Maintenance Interval Schedule
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SMCS Code: 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
Cutting Edges and End Bits - Inspect/Replace ... 106
Engine Air Filter Primary Element - Clean/
Replace ............................................................. 106
Engine Air Filter Secondary Element - Replace .. 107
Engine Air Precleaner - Clean ............................ 108
Ether Starting Aid Cylinder - Replace .................. 115
Front Idler Position - Check ................................. 118
Fuel System - Prime ............................................ 119
Fuses and Circuit Breakers - Replace/Reset ...... 124
Oil Filter - Inspect ................................................ 129
Radiator Core - Clean ......................................... 130
Radiator Pressure Cap - Clean/Replace ............ 131
Ripper Tip and Shank Protector - Inspect/
Replace ............................................................. 133
Trunnion Bearing - Adjust ................................... 143
Winch Wire Rope - Install ................................... 145
Window Washer Reservoir - Fill .......................... 146
Windows - Clean ................................................. 147
Every 10 Service Hours or Daily

Backup Alarm - Test .............................................. 94
Brakes, Indicators and Gauges - Test ................... 96
Cab Filter (Fresh Air) - Clean/Inspect/Replace ..... 99
Cooling System Coolant Level - Check .............. 102
Engine Oil Level - Check .................................... 109
Fuel System Water Separator - Drain ................. 121
Hydraulic System Oil Level - Check ................... 128
Seat Belt - Inspect .............................................. 134
Transmission System Oil Level - Check ............. 142
Every 50 Service Hours or Weekly

Cab Filter (Recirculation) - Clean/Inspect/
Replace ............................................................... 99
Ripper Linkage and Cylinder Bearings Lubricate ........................................................... 133
Track Pins - Inspect ............................................ 137
Initial 100 Service Hours

Trunnion Bearing - Adjust ................................... 143
Every 250 Service Hours

Cooling System Coolant Sample (Level 1) Obtain ............................................................... 103
Every 250 Service Hours or Monthly

Angle Blade Manual Tilt Brace - Lubricate ............ 94
Belts - Inspect/Adjust/Replace .............................. 94
Bulldozer - Lubricate ............................................. 98
Engine Oil Sample - Obtain ................................. 110
Equalizer Bar Center Pin - Lubricate ................... 114
Equalizer Bar End Pins Oil Level - Check ........... 114
Final Drive Oil Level - Check ............................... 116
Fuel Tank Water and Sediment - Drain ............... 123
Pivot Shaft Oil Level - Check .............................. 130
Track - Check/Adjust ........................................... 135
Winch Fairlead Rollers - Lubricate ...................... 144
Winch Oil Level - Check ..................................... 144

Winch Oil and Breather - Change/Clean ............ 145
Every 500 Service Hours

Final Drive Oil Sample - Obtain ........................... 117
Hydraulic System Oil Sample - Obtain ............... 128
Transmission System Oil Sample - Obtain ......... 142
Every 500 Service Hours or 3 Months

Engine Crankcase Breather - Clean ................... 108
Engine Oil and Filter - Change ............................ 111
Fuel System Secondary Filter - Replace ............ 120
Fuel System Water Separator Element Replace ............................................................. 121
Fuel Tank Cap Filter and Strainer Replace/Clean .................................................. 123
Hydraulic System Oil Filter - Replace ................. 127
Recoil Spring Compartment Oil Level - Check ... 131
Transmission Breather - Clean ........................... 138
Window Wipers - Inspect/Replace ...................... 146

Engine Valve Lash - Check/Adjust ....................... 114
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Every 1000 Service Hours or 6 Months

Battery - Inspect .................................................... 94
Lift Cylinder Yoke Bearings - Lubricate ............... 129
Rollover Protective Structure (ROPS) and Falling
Object Protective Structure (FOPS) - Inspect ... 133
Torque Converter Scavenge Screen - Clean ...... 134
Transmission Breather - Replace ....................... 139
Transmission Scavenge Screen - Clean ............. 139
Transmission System Oil - Change .................... 139
Transmission System Oil Filter - Replace ........... 141
Winch Oil and Breather - Change/Clean ............ 145
Every 2000 Service Hours or 1 Year

Final Drive Oil - Change ...................................... 116
Hydraulic System Oil - Change ........................... 125
Track Roller Frame Guides - Inspect .................. 137
Every Year
Engine Air Filter Secondary Element - Replace .. 107
Refrigerant Dryer - Replace ................................ 132
Every 3 Years After Date of Installation or

Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 134
Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .. 100
Cooling System Water Temperature Regulator Replace ............................................................. 105
Every 6000 Service Hours or 4 Years

Engine Valve Lash - Check/Adjust ....................... 114
Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 99
93
Maintenance Section
94
Maintenance Section
Angle Blade Manual Tilt Brace - Lubricate
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Angle Blade Manual Tilt Brace

- Lubricate
SMCS Code: 6074-086
If equipped:
Illustration 128
g01043892
i01376996
Battery - Inspect
SMCS Code: 1401-040
Illustration 127
g00103702
Lubricate the two fittings. Use Multipurpose Lithium

Complex Grease with Molybdenum (MPGM).
i02431451
Backup Alarm - Test

SMCS Code: 7406-081
1. Open the battery access covers. The battery

access covers are located on the left side of the
machine outside the operator compartment.
2. Tighten the battery retainers. Clean the top of the
batteries with a clean cloth. Keep the terminals
clean and coated with petroleum jelly. Install the
terminal covers after you coat the terminals.
3. Close the battery access covers.
The backup alarm is on the rear of the machine.

In order to test the alarm for proper functioning, turn
the engine start switch to the ON position.
Apply the service brake. Release the parking brake.
Move the speed range selector to the REVERSE
position.
The backup alarm should start to sound immediately.
The backup alarm will continue to sound until the
speed range selector is moved to the NEUTRAL
position or to the FORWARD position.
i02274792
Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510
Inspect
1. Open the access door on the right side of the
machine. Open the access door on the left side of
the machine in order to inspect the air conditioning
compressor belt.
Note: Even if only one belt is worn or damaged,
replace the belts in sets.
2. Inspect the condition of the fan drive belt, the
alternator and water pump belt, and the air
conditioning compressor belt. The belts should
deflect 14 to 20 mm (.56 to .81 inch) under 110 N
(25 lb) of force. Use a 144-0235 Belt Tension
Gauge in order to measure the tension.
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95
Maintenance Section
Belts - Inspect/Adjust/Replace
Adjust/Replace
Illustration 130
Illustration 129
g00850323
Alternator and Water Pump Belt
1. Loosen bolts (1).

2. Turn adjusting nuts (2) until the correct belt tension
is reached. To achieve the correct belt adjustment,
move the alternator inward or move the alternator
outward, as required.
g00850322
Fan Drive Belt

2. Turn the adjusting nuts (2) until the correct belt
tension is reached. To achieve the correct belt
adjustment, move the idler pulley inward or move
the idler pulley outward, as required.
3. Tighten bolts (1).
Illustration 131
Air conditioning compressor belt
g01147368
96
Maintenance Section
Brakes, Indicators and Gauges - Test
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2. Turn adjusting nuts (2) until the correct belt

tension is reached. To achieve the correct belt
adjustment, move the compressor inward or move
the compressor outward, as required.
ON The engine start switch key (1) must

be turned to the ON position in order to
supply electrical power to the operators
compartment so that the CMS will function.
4. Close the access doors.
Turn the engine start key to the ON position. The

system should act in the following manner:
Note: Use the same procedure in order to replace

the belts.
The indicator lights on the top portion of the
Note: If new belts are installed, check the belt

adjustment again after 30 minutes of engine
operation.
The action light comes on briefly.
i02431458
Brakes, Indicators and Gauges

- Test
SMCS Code: 4100-081; 7000-081; 7450-081
Inspect the dash panel for broken lenses, indicator
lights, and switches.
CMS Functional Test

To ensure proper operation of the CMS, check the
system on a daily basis.
instrument panel come on briefly.
The auxiliary action light comes on briefly.

The indicator lights on the bottom portion of the
instrument panel flash briefly.
The action alarm sounds briefly.

The pointers on the gauges point upward. Then,
the pointers point to the left. Then, the pointers
point to the right. Then, the pointers point to the
final position.
If the system functions properly, start the engine. If

any of the following events occur, do not start the
engine:
The indicator lights on the top portion or the bottom

portion of the instrument panel do not come on.
The action light does not come on.

The auxiliary action light does not come on.
The action alarm does not sound.
Complete any necessary repairs before you start
the engine.
Panel Test Switch With the engine
stopped, push test switch (2). Service hours
will appear in the display area until the
switch is pushed. Push the switch and release the
switch until the desired information appears in the
display area. The following type of information is
displayed:
Total Service Hours

Illustration 132
g01043983
The battery disconnect switch must be ON in order

to supply electrical power to the machine so that the
electrical systems will function.
Service hours in forward speed range

Service hours in reverse speed range
Fault codes
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97
Maintenance Section
Brakes, Indicators and Gauges - Test
Braking System (Test)
8. Reduce the engine speed to LOW IDLE. Engage

the parking brake. Lower all attachments to the
ground. Apply a slight down pressure. Stop the
engine.
If the machine moves during the test, reduce the

engine speed immediately, and engage the parking brake.
9. Make any necessary repairs before you operate

the machine.
If the machine moved while testing the brakes,

consult your Caterpillar dealer for brake inspection and repair. Damaged brakes must be repaired
before returning the machine to operation.
NOTICE
If the machine moved while testing the brakes, contact
your Caterpillar dealer. Have the dealer inspect and,
if necessary, repair the service brake before returning
the machine to operation.
Note: The machine is capable of driving through

the brakes in the first speed range.
Make sure that the area around the machine is clear
of personnel and clear of obstacles.
Test the brakes on a dry, level surface.
Fasten the seat belt before you test the brakes.
Illustration 133
g01043985
1. Start the engine.

2. Raise all attachments.
3. Depress the service brake pedal.
4. Release the parking brake.
5. While the brake pedal is depressed, move the
directional control to the SECOND SPEED
FORWARD position.
6. Gradually increase the engine speed to full load
speed. The machine should not move.
7. Move the directional control to the NEUTRAL
position.
98
Maintenance Section
Bulldozer - Lubricate
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i02292200
Bulldozer - Lubricate
(Power Angle Tilt Blade)
SMCS Code: 6050-086
g01147520
Illustration 134
Lubricate the Power Angle Tilt Blade at every 250

hour interval.
1. Lubricate the bearings on the ends of each
hydraulic cylinder (6 points).
2. Lubricate the bearings on each end of the
stabilizer link (2 points).
3. Lubricate the bearings under the cover of the
stabilizer link (2 points).
4. Lubricate the trunnion bearing (1 point).
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99
Maintenance Section
Cab Filter (Fresh Air) - Clean/Inspect/Replace
i02276929
i02277295
Cab Filter (Fresh Air) Clean/Inspect/Replace

(If Equipped)
Cab Filter (Recirculation) Clean/Inspect/Replace

(If Equipped)
SMCS Code: 7342-040; 7342-070-FI; 7342-070;

7342-510; 7342-510-FI
SMCS Code: 7342-040; 7342-070; 7342-510
Illustration 135
g01140074
Top view
1. Remove filter cover (1) and filter element (2). The

filter cover is in front of the front window of the cab.
2. The filter element can be cleaned by using
pressure air. Use a maximum air pressure of
205 kPa (30 psi). Direct the air from the clean side
to the dirty side.
3. Look through the filter toward a bright light. Inspect
the element for damage. Inspect the gaskets for
damage. Replace damaged filters.
4. Install the filter element.
Illustration 136
g01140113
1. Remove the filter element that is positioned in the

operators compartment below the left side of the
dash.
2. The filter element can be cleaned by using
pressure air. Use a maximum air pressure of
205 kPa (30 psi). Direct the air from the clean side
to the dirty side.
3. Look through the filter toward a bright light. Inspect
the element for damage. Inspect the gaskets for
damage. Replace damaged filters.
4. Install the filter element.
Note: Clean the filters more often in dusty conditions.
Note: Clean the filters more often in dusty conditions.

i02277330
Cooling System Coolant (ELC)

- Change
SMCS Code: 1395-044
NOTICE
Make sure you read and understand the information
in the topics Safety and Cooling System Specifications for all information pertaining to water, antifreeze
and supplemental coolant additive requirements before you proceed with maintenance of the cooling system.
100
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
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.
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Note: Caterpillar antifreeze contains additive. 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.
12. Start the engine. Run the engine without the filler
cap until the thermostat opens and the coolant
level stabilizes.
13. Check the coolant level. Make necessary
adjustments to the coolant level.
14. If the gasket is damaged, replace the filler cap.
Install the filler cap.
15. Stop the engine.
Drain the coolant whenever the coolant is dirty or

whenever foaming is observed.
The filler cap is located inside the access door in the
top, left side of the radiator guard.
1. Slowly loosen the filler cap in order to relieve
system pressure. Remove the filler cap.
2. Remove the access cover. The cover is located in
the front, bottom guard.
3. Remove the plug from the drain valve. Install a
12.7 millimeter (.5 inch) pipe into the drain valve.
The pipe requires 1/2 - 14 NPTF threads.
Illustration 137
4. Clamp a hose to the pipe in order to direct the

coolant into a suitable container.
16. Clean the radiator cores with compressed air. You

may need to use water in order to remove debris.
5. Open the drain valve. Allow the coolant to drain

into a suitable container.
6. Close the drain valve. Fill the 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.
7. Start the engine. Run the engine for 90 minutes.
Stop the engine. Drain the cleaning solution into a
suitable container.
8. While the engine is stopped, flush the system with
water. Flush the system until the draining water
is clear.
9. Close the drain valve.
10. Replace the plug in the drain valve and install the
access cover.
11. Add the coolant solution. See the following topics
in this publication:
Refill Capacities
g00533931
i02277360
Cooling System Coolant

Extender (ELC) - Add
SMCS Code: 1395-538
NOTICE
products.
mandates.
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101
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
Table 15
Cat ELC Extender and the Cooling System Capacity

Cooling System Capacity
65 to 83 L (17 to 22 US gal)
Recommended
Amount of Cat
ELC Extender
1.60 L (54 oz)
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.
For additional information about adding an extender,
see Special Publication, SEBU6250, Caterpillar
Machine Fluids Recommendations or consult your
Caterpillar dealer.
1. The filler cap is located inside the access door on

the top, left side of the radiator guard. Loosen the
radiator cap slowly in order to relieve pressure.
Remove the radiator cap.
2. It may be necessary to drain some coolant from
the radiator so that Extender can be added to the
cooling system.
Note: Always discard drained fluids according to
local regulations.
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.
Tools and Shop Products Guide, for tools and supplies suitable to collect and contain fluids in Caterpillar
machines.
Extended Life Coolant (ELC)

Extender
Use a 8T-5296 Coolant Conditioner Test Kit to
check the concentration of the coolant.
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.

mandates.
3. Add 1.60 L (54 oz) of Extender to the cooling
system.
4. Start the engine. Run the engine without the filler
cap until the thermostat opens and the coolant
level stabilizes. Check for leaks.
Remove filler cap slowly to relieve pressure only

when engine is stopped and radiator cap is cool
enough to touch with your bare hand.
Cooling System Conditioner contains alkali. Avoid
contact with skin and eyes.
Illustration 139
g00475722
5. Look into filler tube (1). If necessary, add premixed

coolant in order to correct the coolant level.
Maintain the coolant level between area (2) and
area (3) of the filler tube. Adding coolant above
this area of the filler tube will cause the coolant to
overflow the cooling system.
Illustration 138
g01140173
6. Replace the radiator cap if the cap gasket is

damaged. Install the radiator cap.
102
Maintenance Section
Cooling System Coolant Level - Check
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i02277501
Cooling System Coolant Level

- Check
SMCS Code: 1353-535-FLV; 1395-535-FLV
Note: The factory fill is Extended Life Coolant

(ELC). Refer to Operation and Maintenance
Manual, SEBU6250, Caterpillar Machine Fluids
Recommendations for additional information.
Maintaining the system as ELC is preferred. See
the sections Coolant Recommendations and ELC
Cooling System Maintenance.
At operating temperature, the engine coolant is

hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine has
been stopped and the fill cap is cool enough to
touch with your bare hand.
Remove the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent personal
injury.
This machines radiator has a surge tank. There
is no top tank in this cooling system. The surge
tank has a filler cap and a sight glass. It is not
necessary to remove the filler cap in order to check
the coolant level. The sight glass is inside the engine
compartment that is on the front left side of the
machine. The filler cap is beneath the access door
that is on the top left side of the radiator guard.
Illustration 141
2. If it is necessary to add coolant, remove the filler

cap slowly in order to relieve the pressure.
Illustration 142
Illustration 140
g01140272
1. Observe the sight glass in order to verify the level

of the coolant. If the coolant completely covers the
sight glass, the coolant level is okay. If the coolant
level is visible in the sight glass, the coolant is low.
Add coolant in order to fill the system.
g01140173
g00475722
3. Look into filler tube (1). Maintain the coolant level

between area (2) and area (3) of the filler tube.
Adding coolant above this area of the filler tube
will cause the coolant to overflow the cooling
system. If you need to add coolant daily, check the
cooling system for leaks.
4. Inspect the filler cap and the filler cap seal for
debris, for foreign material, or for damage. Clean
the filler cap with a clean cloth. Replace the
radiator cap if the filler cap is damaged.
5. Install the filler cap.
6. Inspect the radiator core for debris. Clean the
radiator core, if necessary.
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103
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
Use compressed air, high pressure water, or steam

to remove dust and debris from the radiator core.
However, the use of compressed air is preferred.
i02277521
Testing the coolant can be done at your Caterpillar

dealer. Caterpillar SOS Coolant Analysis is the best
way to monitor the condition of your coolant and your
cooling system. SOS Coolant Analysis is a program
that is based on periodic samples.

Sample (Level 1) - Obtain
Perform a Coolant Analysis (Level 1 ) at 250 hours

for systems that do not contain extended life coolant
(ELC).
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Use the following guidelines for proper sampling of

the coolant:
Obtain the sample of the coolant as close as possible

to the recommended sampling interval. In order
to receive the full effect of SOS analysis, you
must establish a consistent trend of data. In order
to establish a pertinent history of data, perform
consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.
Level 1 Analysis
NOTICE
products.
Complete the information on the label for the

sampling bottle before you begin to take the
samples.
Keep the unused sampling bottles stored in plastic

bags.
Obtain coolant samples directly from the coolant

sample port. You should not obtain the samples
from any other location.
Keep the lids on empty sampling bottles until you

are ready to collect the sample.
Place the sample in the shipping sleeve
immediately after obtaining the sample in order to

avoid contamination.
Never collect samples from expansion bottles.

Never collect samples from the drain for a system.

mandates.
Note: It is not necessary to obtain a Coolant
Sample (Level 1) if the cooling system is filled
with Cat ELC (Extended Life Coolant). Cooling
systems that are filled with Cat ELC should have
a Coolant Sample (Level 2) that is obtained at
the recommended interval that is stated in the
Maintenance Interval Schedule.
Note: Obtain a Coolant Sample (Level 1) if the
cooling system is filled with any other coolant
instead of Cat ELC. This includes the following
types of coolants.
Commercial long life coolants that meet the

Caterpillar Engine Coolant Specification -1
(Caterpillar EC-1)
Cat Diesel Engine Antifreeze/Coolant (DEAC)
Commercial heavy-duty coolant/antifreeze
Illustration 143
g01140364
Right view
1. Park the machine on a hard, level surface. Set the

engine at low idle speed.
2. Open the right engine compartment. Remove the
protective cap from the sampling valve.
104
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
3. Obtain a sample. For additional information

about coolant analysis, see Special Publication,
SEBU6250, Caterpillar Machine Fluids
Recommendations or consult your Caterpillar
dealer.
4. Replace the protective cap. Close the right side
engine compartment.
Submit the sample for Level 1 analysis.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both
dealers and customers.
Note: Level 1 results may indicate a need for
Level 2 Analysis.
Level 2 is a comprehensive analysis which should be
performed annually. See Operation and Maintenance
Manual, Cooling System Coolant Sample (Level 2) Obtain for more information.
i02277557
SEBU7925-08
NOTICE
products.
mandates.
Testing the coolant can be done at your Caterpillar
dealer. Caterpillar SOS Coolant Analysis is the best
way to monitor the condition of your coolant and your
cooling system. SOS Coolant Analysis is a program
that is based on periodic samples. See Operation
and Maintenance Manual, SEBU6250, Caterpillar
Machine Fluid Recommendations, S.O.S Coolant
Analysis for more information.
Perform a Coolant Analysis (Level 2) at initial 500
hours for systems that contain extended life coolant
(ELC). Perform the analysis yearly after the initial
500 hours.

Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Level 2 Analysis
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both
dealers and customers.
Illustration 144
g01140364
1. Park the machine on a hard, level surface. Set the

engine at low idle speed.
2. Open the right side engine compartment. Remove
the protective cap from the sampling valve.
3. Obtain a sample. For additional information
about coolant analysis, see Special Publication,
SEBU6250, Caterpillar Machine Fluids
Recommendations or consult your Caterpillar
dealer.
4. Replace the protective cap. Close the left side
engine compartment.
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105
Maintenance Section
Cooling System Water Temperature Regulator - Replace
Submit the sample for Level 2 analysis.

i02277639
Cooling System Water

Temperature Regulator Replace
SMCS Code: 1355-510
NOTICE
Illustration 145

products.
3. Remove the bolts from the elbow. Remove the

elbow and the thermostat housing assembly.

mandates.
Replace the thermostat on a regular basis per the
maintenance interval schedule. This reduces the
chance of unscheduled downtime and of problems
with the cooling system.
A new thermostat should be installed after the cooling
system has been cleaned. Install the thermostat
while the cooling system is completely drained or
while the cooling system coolant is drained to a level
that is below the thermostat housing.
NOTICE
Failure to replace the engines thermostat on a regularly scheduled basis could cause severe engine damage.
Note: If you are only installing a new thermostat,
drain the cooling system coolant to a level that is
below the thermostat housing.
1. Open the right engine compartment.
g01144256
2. Loosen the hose clamp and remove the hose from

the elbow. Disconnect the hose assembly from
the thermostat housing assembly.
4. Remove the gaskets, the thermostat, and the seal

from the thermostat housing.
NOTICE
Since Caterpillar engines incorporate a shunt design
cooling system, it is mandatory to always operate the
engine with the thermostats.
Depending on load, failure to operate with the thermostats could result in either an overheating or an
overcooling condition.
NOTICE
If the thermostat is installed incorrectly, it will cause
the engine to overheat.
5. Install a new seal in the thermostat housing. Install
the new thermostat and the new gasket. Install the
thermostat housing on the engine cylinder head.
6. Install the elbow and the hose. Tighten the hose
clamp.
7. Close the right engine compartment.
8. Replace the coolant that was drained from the
system. Refer to Operation and Maintenance
Manual, Capacities (Refill).
106
Maintenance Section
Cutting Edges and End Bits - Inspect/Replace
i02050518
Cutting Edges and End Bits Inspect/Replace
SEBU7925-08
8. Raise the bulldozer blade and remove the

blocking. Lower the bulldozer blade to the ground.
9. After you operate the machine for a few hours,
check all bolts for the proper torque.
SMCS Code: 6801-040; 6801-510; 6804-040;

6804-510
i02229305
Engine Air Filter Primary

Element - Clean/Replace
SMCS Code: 1051-070; 1051-510-PY; 1054-070-PY;
1054-510-PY
NOTICE
Service the primary filter element only when the alert
indicator for the intake air filter is flashing. Do not open
the filter compartment unless it is time for service.
Opening the filter compartment can cause dirt to get
into the clean side of the filter housing.
Illustration 146
g01051836
1. Raise the bulldozer blade and block up the

bulldozer blade. When you remove the cutting
edges and the end bits, maintain the bulldozer
blade at a minimum height.
2. Remove the bolts. Then remove the cutting edge
and the end bits.
3. Thoroughly clean all contact surfaces.
4. Inspect the opposite side of the cutting edge. If
the opposite side of the cutting edge is not worn,
turn the opposite side of the cutting edge outward
and install the cutting edge.
5. If both sides of the cutting edge are worn, install a
new cutting edge section.
Note: When the cutting edge is within 10 mm
(0.4 inch) of the bottom of the support, change the
cutting edge. Do not allow wear to occur on the
support.
6. If the bottom edge or the outside edge of the end
bit is worn, install a new end bit.
Note: When the end bit is within 10 mm (0.4 inch) of
the bottom of the support, change the end bit. When
the end bit is within 10 mm (0.4 inch) of the outside
edge of the support, change the end bit. Do not
allow any wear to occur on the support.
7. Install all bolts and tighten the bolts to the specified
torque. Refer to Operation and Maintenance
Manual, Torques for Ground Engaging Tools.
NOTICE
Extremely short air filter life can result if the precleaner system malfunctions. If air filter life is drastically reduced from typical for the operating conditions, consult your Caterpillar Dealer. The exhaust system dust
ejector for the strata tube precleaner must pull a minimum vacuum of 508 mm (20 inch) of water.
NOTICE
Service the engine air filters with the engine stopped.
Engine damage could result.
NOTICE
Always leave the secondary filter element in place
while you clean the primary element, or while you
clean the air cleaner housing.
NOTICE
Do not use the filter for longer than one year.
1. Open the engine compartments access door, if
equipped.
SEBU7925-08
107
Maintenance Section
Engine Air Filter Secondary Element - Replace
7. Inspect the primary filter element. Inspect the

filter element for holes and for tears by looking
through the filter element. Look toward a bright
light. Inspect the element for damaged gaskets or
for dented metal parts. Replace damaged filters.
Always crush damaged filter elements. Properly
discard the filter elements. If you replace the
primary filter element, proceed to step 9.
Illustration 147
g00470852
2. Remove the air cleaner cover (1). Pull out in order

to remove the element.
3. Remove the primary filter element (2) from the air
cleaner housing.
4. Mark the secondary filter element in order to show
that the primary filter element has been serviced.
The secondary filter element should be replaced
when the primary filter element is serviced for the
third time. Refer to Operation and Maintenance
Manual, Engine Air Filter Secondary element Replace.
8. If the primary filter element is not damaged and

the element has not been previously cleaned six
times, clean the element. The filter element can
be cleaned by using pressure air. Use a maximum
air pressure of 205 kPa (30 psi). Direct the air
from the clean side to the dirty side. In order to
show that the filter element has been cleaned,
mark the element. The primary filter element can
be cleaned up to six times.
NOTICE
Do not clean the filter elements by bumping or tapping
them. Do not use filter elements with damaged pleats,
gaskets, or seals. Do not wash the filter elements.
9. Push the filter element firmly in order to properly
seat the element. Write the date on the element, if
the primary element is replaced.
10. Install the air cleaner cover.
11. Close the access door, if equipped.
i02281102
Engine Air Filter Secondary

Element - Replace
SMCS Code: 1051-510-SE; 1054-510-SE
NOTICE
Always replace the secondary filter element. Never
attempt to reuse it by cleaning.
Illustration 148
g00470857
5. Clean the inside of the air cleaner housing. Keep

the secondary filter element in place while you
clean the housing.
6. If the primary filter element has not been cleaned
six times, inspect the primary filter element. If
the primary filter element has been cleaned six
times, replace the primary filter element. Proceed
to Step 9.
The secondary filter element should be replaced at the

time the primary element is serviced for the third time.
The secondary filter element should also be replaced
if the yellow piston in the filter element indicator enters the red zone after installation of a clean primary
element, or if the exhaust smoke is still black.
NOTICE
Do not use the filter for longer than one year.
108
Maintenance Section
Engine Air Precleaner - Clean
SEBU7925-08
NOTICE
Always leave the secondary filter element in place
while you clean the primary element, or while you
clean the air cleaner housing.
7. Install a new secondary filter element. Push

the element firmly in order to properly seat the
element. Write the date on the new primary
filter element, when you install the primary filter
element in the machine.
8. Install the primary filter element and the air cleaner
housing cover. Tighten the bolts for the air cleaner
housing cover finger tight. Do not use a tool to
tighten the bolts for the air cleaner housing cover.
9. Close the engine access door, if equipped.
i02281103
Engine Air Precleaner - Clean

SMCS Code: 1050-070
Illustration 149
g01141636
1. Open the engine access door, if equipped. The

engine access door is located on the left side of
the machine outside the operators compartment.
2. Remove the air cleaner housing cover.
3. Remove the primary filter element.
Reference: Refer to Operation and Maintenance
Manual, Engine Air Filter Primary Element Clean/Replace.
4. Cover the air inlet opening. Clean the inside of
the air cleaner housing.
5. Inspect the gasket between the air inlet and the
air cleaner housing. If the gasket is damaged,
replace the gasket.
Illustration 151
g01141638
1. Inspect the air inlet screen for dirt and for trash.
2. Remove the screen. Clean the screen if the
screen is dirty.
3. Inspect the precleaner tubes for dirt and for dust.
4. Use pressure air to clean the tubes. Put the tubes
on a flat surface. Direct the pressurized air into
the tubes from the top. This loosens up the dirt.
Install the screens.
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.
i02760445
Illustration 150
g00470240
6. Uncover the air inlet opening. Remove the

secondary filter element. Pull out in order to
remove the element.
Engine Crankcase Breather Clean

SMCS Code: 1317-070
1. Open the left engine access door.
SEBU7925-08
109
Maintenance Section
Engine Oil Level - Check
i02281109
Engine Oil Level - Check

SMCS Code: 1302-535-FLV; 1326-535-FLV
Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact
skin.
Illustration 152
g01381893
2. Loosen the breather outlet hose clamp. Remove

the hose from the engine crankcase breather.
NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
1. The level gauge relies on gravity. The machine
must be on a level surface for an accurate check.
2. Open the engine access cover that is on the left
side of the machine.
Illustration 153
g01249976
3. Loosen the breather inlet hose clamp. Remove

the engine crankcase breather.
4. Check the condition of the cover seal. Replace the
cover seal if the cover seal is damaged.
5. Wash the breather element and the breather
element cover assembly in a clean nonflammable
solvent.
6. Shake the breather element until the breather
element is dry. You may also use pressure air to
dry the breather element.
7. Check the condition of the hoses. Make sure that
the inside of the hoses are unobstructed. Replace
a hose if the hose is damaged.
8. Install the breather element cover assembly.
9. Install the hoses, the breather outlet hose clamp,
and the breather inlet hose clamp.
10. Close the engine access door.
Illustration 154
g01141640
3. Check the dipstick while the engine is stopped

and the oil is at operating temperature. Maintain
the oil level in the operating area on the dipstick.
The operating area is between the add oil mark
and the full mark.
Note: When you operate the machine on severe
slopes, the oil level in the engine crankcase must be
at the full mark on the dipstick.
110
Maintenance Section
Engine Oil Sample - Obtain
SEBU7925-08
Obtain the sample of the engine oil as close as

possible to the recommended sampling interval. The
recommended sampling interval is every 250 service
hours. In order to receive the full effect of SOS oil
analysis, you must establish a consistent trend of
data. In order to establish a pertinent history of data,
perform consistent oil samplings that are evenly
spaced.
1. Open the engine access door on the right side of
the machine.
Illustration 155
g01141645
4. Remove the oil filler cap. If necessary, add oil.

5. Clean the oil filler cap and install the oil filler cap.
6. Close the access cover.
i02281124
Engine Oil Sample - Obtain

SMCS Code: 1348-554-SM; 1348; 7542

skin.
NOTICE
products.
mandates.
Illustration 156
g01141648
2. Remove the protective cap.

3. Use 169-8373 Fluid Sampling Bottle in order to
obtain a sample of the engine oil.
4. Replace the protective cap.
Refer to Operation and Maintenance Manual,
Lubricant Viscosities for the correct fluid for your
machine.
SEBU7925-08
111
Maintenance Section
Engine Oil and Filter - Change
i02281129
Table 16
D6R Series III

Engine Oil Change Interval(1)
SMCS Code: 1308; 1318-510
Operating Conditions
Severe
Selection of the Oil Change Interval

NOTICE
This machine is equipped with an engine that meets
EPA Tier 2, Euro Stage II, or MOC Step 2 emission
regulations. A 500 hour engine oil change interval is
available, provided that operating conditions and recommended multigrade oil types are met. When these
requirements are not met, shorten the oil change
interval to 250 hours, or use an SOS oil sampling
and analysis program to determine an acceptable oil
change interval.
Normal(2)
Multigrade
Oil Type
High
Load
Factor(3)
above
32 L (8.5
US gal)
per hr
of fuel
Fuel
Sulfur
from
0.3% to
0.5%
Altitude
above
1830 m
(6000 ft)
(4)
Cat DEO
Preferred
500 hr
500 hr
500 hr
250 hr(6)
API CH-4
11.0
minimum
TBN(4)
Preferred
500 hr
500 hr
500 hr
250 hr(6)
Caterpillar oil filters are recommended.
API CH-4
TBN(4)
below 11.0
500 hr
500 hr
250 hr(5)
250 hr(6)
Recommended multigrade oil types are listed in Table

16. Do not use single grade oils.
API CG-4
500 hr
250 hr(5)
250 hr(5)
250 hr(6)
If you select an interval for oil and filter change that is

too long, you may damage the engine.
Illustration 157
g00753767
API Symbol
Commercial oils that are licensed by the American Petroleum
Institute (API) bear this symbol. Commercial oils that do not bear
this symbol are not licensed and these oils are not recommended.
Oils that are not listed in Table 16 are not recommended.
Abnormally harsh operating cycles or harsh

environments can shorten the service life of
the engine oil. Arctic temperatures, corrosive
environments, or extremely dusty conditions may
require a reduction in engine oil change intervals
from the recommendations in Table 16. Also refer
to Special Publication, SEBU5898, Cold Weather
Recommendations For All Caterpillar Machines.
Poor maintenance of air filters or of fuel filters
requires reduced oil change intervals. See your
Caterpillar dealer for more information if this product
will experience abnormally harsh operating cycles or
harsh environments.
(1)
The traditional oil change interval for engines is 250 hours.

The standard oil change interval in this machine is 500 hours, if
the operating conditions and recommended oil types that are
listed in this table are met. Improvements in the engine allow
this engine oil change interval. This new standard interval is not
permitted for other machines. Refer to the applicable Operation
and Maintenance Manuals for the other machines.
(2) Normal conditions include these factors: Fuel sulfur below
0.3%, altitude below 1830 m (6000 ft), and good air filter and
fuel filter maintenance. Normal conditions do not include high
load factor, harsh operating cycles, or harsh environments.
(3) High load factors can shorten the service life of your engine
oil. Continuous heavy load cycles and very little idle time
result in increased fuel consumption and oil contamination.
These factors deplete the oil additives more rapidly. If the
average fuel consumption of your D6R Series III exceeds
32 L (8.5 US gal) per hour, follow the High Load Factor
recommendations in Table 16. To determine average fuel
consumption, measure average fuel consumption for a period
of 50 to 100 hours. If the application of the machine is changed,
the average fuel consumption may change.
(4) For sulfur content above 0.5%, refer to Operation and
Maintenance Manual, Total Base Number (TBN) and Fuel
Sulfur Levels for Direct Injection (DI) Diesel Engines in
Manual, SEBU6250.
(5) In order to verify an oil change interval of 500 hours, refer to
Program A below.
(6) Use Program B below to determine an appropriate interval.
Adjustment of the Oil Change Interval

Note: Your Caterpillar dealer has additional
information on these programs.
Program A
Verification for an Oil Change Interval of 500 Hours
112
Maintenance Section
SEBU7925-08
This program consists of three oil change intervals of

500 hours. Oil sampling and analysis is done at 250
hours and 500 hours for each of the three intervals
for a total of six oil samples. The analysis includes
oil viscosity and infrared (IR) analysis of the oil. If
all of the results are satisfactory, the 500 hour oil
change interval is acceptable for the machine in that
application. Repeat Program A if you change the
application of the machine.
NOTICE
If a sample does not pass the oil analysis, take one

of these actions:

products.
Shorten the oil change interval to 250 hours.

Proceed to Program B.

mandates.
Change to a preferred oil type in Table 16.

Program B
Optimizing Oil Change Intervals
Begin with a 250 hour oil change interval. The oil
change intervals are adjusted by increments. Each
interval is adjusted an additional 50 hours. Periodic oil
sampling and analysis is done during each interval.
The analysis includes oil viscosity and infrared (IR)
analysis of the oil. Repeat Program B if you change
the application of the machine.
If an oil sample does not pass the analysis, shorten
the oil change interval, or change to a preferred
multigrade oil type in the listing above.
References
Illustration 158
g01141650
Left view
If the machine is equipped with a high speed oil

change, use a 126-7539 Nozzle.
Reference: Form, PEDP7035, Optimizing Oil

Change Intervals
Reference: Form, PEDP7036, SOS Fluid Analysis
Reference: Form, PEDP7076, Understanding the
SOS Oil Analysis Tests
Procedure for Changing the Engine

Oil and Filter
g01144346
Illustration 159

skin.
1. Remove the bolt in order to remove the crankcase

drain access cover, which is in the crankcase
guard.
Top view
SEBU7925-08
113
Maintenance Section
7. Apply a thin coat of oil to the seal on the new filter.

Install the new engine oil filter element by hand.
When the gasket contacts the filter base, tighten
the filter element by an additional 3/4 turn (270
degrees). Rotation index marks are on the new
filter element. These rotation index marks are
spaced at 90 degree intervals. Use these rotation
index marks as a guide for proper tightening.
Illustration 160
g01150683
(1) drain valve

(2) shutoff valve
(3) drain valve elbow
(A) Left view
(B) Rear view
2. Install a drain hose (not shown) onto drain valve

elbow (3).
Illustration 162
g01144360
3. Open shutoff valve (2). Allow the oil to drain into a

suitable container.
8. Open the left engine access door.
4. When the oil has completed draining from the

crankcase, close shutoff valve (2). Remove the
hose. Install the crankcase drain access cover in
the crankcase guard.
9. Remove oil filler cap (4). Fill the crankcase with

new oil. See the topic Operation and Maintenance
Manual, Refill Capacities in this manual. Clean
oil filler cap (4) and install oil filler cap (4).
10. To ensure that the correct amount of oil was
added, always measure the oil level with the
engine oil dipstick (5).
Check the ENGINE STOPPED side of the
dipstick while the engine is stopped. The oil should
be cold. Maintain the oil level between the LOW
mark and the FULL mark. This method should
be used as reference only, before the engine is
started.
Illustration 161
g01144354
5. Open the engine access door on the right side of

the machine.
6. Remove the engine oil filter element and discard
the engine oil filter element properly. Make sure
that all of the old filter seal is removed from the
filter base.
11. Check the LOW IDLE side of the dipstick

while the engine is running. The oil should be
at operating temperature. Maintain the oil level
between the ADD mark and the FULL mark.
This is the only accurate way to check the oil level.
12. Close the engine access doors.
114
Maintenance Section
Engine Valve Lash - Check/Adjust
SEBU7925-08
i01959327
Engine Valve Lash Check/Adjust

SMCS Code: 1102-025; 1102
To prevent possible injury, do not use the starter

motor to turn the flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before measuring valve clearance.
Illustration 163
g01139573
8F-9866 Grease Gun
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
NOTICE
Operation of Caterpillar engines with improper valve
adjustments will reduce engine efficiency. This reduced efficiency could result in excessive fuel usage
and/or shortened engine component life.
NOTICE
Measure the valve clearance with the engine stopped.
To obtain an accurate measurement, allow at least 20
minutes for the valves to cool to engine cylinder head
and engine block temperature.
Check the valve bridge before setting the valve lash.
Ensure that the valve bridge is seated equally on
both valve stems.
Refer to your machines Service Manual or your
Caterpillar dealer for the complete valve adjustment
procedure.
Illustration 164
g01139561
Remote Fitting
Lubricate the equalizer bar center pin through the

remote fitting. The remote fitting is located on the
frame on the left side of the machine. The fitting is
located below the dipstick.
The proper lubricant for the center pin is the Desert
Gold. NLGI 2 grease
Refer to Operation and Maintenance Manual,
SEBU6250, Lubricating Greases for more
information.
i02428064
Equalizer Bar Center Pin Lubricate

SMCS Code: 7206-086-PN; 7207-086-PN
NOTICE
Apply lubricant to the fittings with a hand operated
grease gun only. Use of pressure operated lubricating
equipment damages the seals.
i02013412
Equalizer Bar End Pins Oil

Level - Check
SMCS Code: 7206-535
NOTICE
Apply gear oil through the fittings with a hand operated lubrication pump or a suitable grease gun. Use
of pressure operated lubricating equipment damages
the seals.
SEBU7925-08
115
Maintenance Section
Ether Starting Aid Cylinder - Replace
NOTICE
Before and after the equalizer bar end pin is filled with
gear oil, seal (1) must be flush with the equalizer bar. If
the seals are not flush, damage to the seals can result
by overfilling.
6. Be sure that seals (1) are not pushed out. Push

back the seals if the seals are pushed out.
7. Install plug (2).
Note: MPGM GREASE IS ALLOWED ONLY
FOR A FAILED SEAL. THE SEAL SHOULD
BE REPLACED AS SOON AS POSSIBLE. THE
COMBINATION OF GEAR OIL AND MPGM IS NOT
HARMFUL TO THE MACHINE.
When you operate the machine in arctic conditions,
lubricate the equalizer bar with EMGARD EP 75W90
gear lubricant. EMGARD EP 75W90 gear lubricant is
a synthetic lubricant. This lubricant is available from
Hudson Corporation.
i02274149
Illustration 165
g00586840
Ether Starting Aid Cylinder Replace

SMCS Code: 1456-510-CD
Illustration 166
g00586858
1. Clean the areas that are around the end pin with a
high pressure wash. Inspect the condition of the
seal (1).
2. Check the area for oil leakage. Be sure that the
seal is in a neutral position.
3. Remove plug (2).
4. Check the oil level. Oil level (4) should be at the
top of the hex head on the fitting.
5. If the oil level is low, apply the gear oil through
fitting (3) until the gear oil reaches oil level (4) at
the top of the hex head on the fitting. Remove
any excess oil. This will maintain a volume of air.
The gear oil must be applied with a 7H-1680
Lubrication Hand Pump. Refer to Operation and
Maintenance Manual, Lubricant Viscosities for
the correct oil. The gear oil has excellent load
carrying capacity.
Illustration 167
g01138860
1. Remove the upper engine compartment access

cover on the left side of the machine.
1. The ether canister is mounted on the bracket
assembly which is seated toward the front of the
cab. Loosen the retaining clamp. Remove the old
canister by turning the canister counterclockwise.
2. Install the Quick Start canister. Turn the canister
clockwise. Hand tighten the canister in order to
seal the gasket to the canister. Tighten the clamp
around the canister.
Note: The ether starting aid cylinder must be installed
with the appropriate gasket. The gasket must be
clean in order to make a proper seal.
3. Close the upper engine compartment access
cover.
116
Maintenance Section
Final Drive Oil - Change
SEBU7925-08
i02281340
Final Drive Oil - Change
4. Inspect the drain plug seal. Replace the drain plug

seal if the drain plug seal is damaged.
5. Clean the drain plug and install the drain plug.
SMCS Code: 4050-535-FLV
6. Fill the final drive with oil to the bottom of the filler
plug opening. See Operation and Maintenance
Manual, Capacities Refill.
skin.
NOTICE
products.
7. Inspect the condition of the seal of the filler plug.

Replace the plug seal if the plug seal is damaged.
Wipe the magnet in order to clean the plug. Install
the plug.
8. Repeat Step 1 to Step 7 in order to change the oil
in the other final drive.
For additional information about final drive oil, see
Special Publication, SEBU6250, Caterpillar Machine
Fluids Recommendations or consult your Caterpillar
dealer.
i02281354
Final Drive Oil Level - Check


mandates.
skin.
Illustration 168
g01141777
1. Position one final drive so that oil level mark (1) is

horizontal. The drain plug (3) will point downward.
2. Remove oil filler plug (2).
Illustration 169
3. Remove drain plug (3). Allow the oil to drain into a

suitable container.
g01141777

horizontal and drain plug (3) is at the bottom.
SEBU7925-08
117
Maintenance Section
Final Drive Oil Sample - Obtain

3. The oil level should be at the bottom of the filler
plug opening. Add oil, if necessary.
See the Table in the article Lubricant Viscosities
for the type of oil.
4. Install oil filler plug (2).
5. Repeat Step 1 to Step 4 in order to check the oil
level in the other final drive.
i02281399
Final Drive Oil Sample - Obtain

SMCS Code: 3258-008; 4011-008; 4050-008;
4050-SM; 4070-008; 4070-554-SM; 7542-008
Illustration 170
g01141813

horizontal. Drain plug (3) should face downward.

skin.
2. Remove oil filler plug (2) and obtain the oil sample
with a 1U-5718 Vacuum Pump.
NOTICE
Note: Do not use the drain stream method to obtain

a sample of the final drive oil. A stream of dirty oil
from the bottom of the compartment will contaminate
the sample. Likewise, never dip an oil sample from
an oil container or pour a sample from a used filter.

products.
4. Repeat Step 1 to Step 3 in order to sample the oil

in the other final drive.

mandates.
Obtain the sample of the differential and final drive oil
as close as possible to the recommended sampling
interval. The recommended sampling interval is every
500 service hours. In order to receive the full effect
of SOS oil analysis, you must establish a consistent
trend of data.
3. Install oil filler plug (2).
Reference: Refer to, Lubricant Viscosities in the

Maintenance Section of this manual for the correct
fluid for your machine.
Reference: Refer to Special Publication, SEBU6250,
Caterpillar Machine Fluids Recommendations,
SOS Oil Analysis for information that pertains
to obtaining a sample of the final drive oil. Refer
to Special Publication, PEHP6001, How To Take
A Good Oil Sample for more information about
obtaining a sample of the final drive oil.
118
Maintenance Section
Front Idler Position - Check
SEBU7925-08
i02296034
Front Idler Position - Check

SMCS Code: 4159
SystemOne Undercarriage
The following check is for Caterpillar SystemOne
Undercarriages that have the center tread idler.
Illustration 172
g01151486
Adjustment shim (center tread idler)
5. For machines with the SystemOne Undercarriage,

remove one shim under each track idler block
when the wear on the link and roller system is at
50%.
Consult your Caterpillar dealer for detailed
information about adjustments to the center tread
idler.
See Operation and Maintenance Manual, Track
- Check/Adjust for information on needed track
adjustments.
Illustration 171
g01149978
Elevated undercarriage system
1. Park the machine on a hard, flat surface. Make

sure that the bottom track is tight and that the
measured grouser lies directly below the track
idler shaft.
Reference: See Operation and Maintenance

Manual, Reference Material for publications and
Special Instructions on removal and installation of
SystemOne Track, as needed.
Conventional Design
2. Measure the height (A, B) from the flat ground

surface to the grouser tip that is centered below
the track idler shaft.
3. Maintain the grouser height (rise) to the following
dimensions.
a. (A) Front Idlers
Minimum 0 mm (0 inch)
Maximum 20 mm (0.8 inch)
b. (B) Rear Idlers
Minimum 10 mm (0.4 inch)
Maximum 40 mm (1.6 inch)
4. Repeat Steps 1 through 3 in order to determine
the proper height dimension under each idler.
Illustration 173
g00669323
(A) Adjusting shims

(B) Dimension between the height of the front idler tread and the
height of the roller tread
The following check is for undercarriage systems that

have the conventional idler.
SEBU7925-08
119
Maintenance Section
Fuel System - Prime
The height of the front idler tread should always

be higher than the height of the roller tread.
The dimension (B) is set approximately to 9.0 mm
(.35 inch) at the factory. Dimension (B) decreases
as the undercarriage wears. If a rebuilt idler or a
new idler is installed with track rollers that are worn,
dimension (B) decreases.
Adjustment of the front idler to the correct height can
improve the ride of the tractor and the performance of
the dozer. Use the following procedures to determine
the best operating position.
If the machine is operated on FIRM UNDERFOOT
conditions and excess vibration occurs, shims can be
removed in order to raise the front idler.
If the machine is operated on SOFT UNDERFOOT
conditions and dozing performance is poor, shims can
be installed in order to lower the front idler. Lowering
the front idler can improve dozing performance. If
ground rippling by the dozer or excess vibration occur
in soft material, shims can be removed in order to
raise the front idler.
Consult your Caterpillar dealer for detailed
information about checking the idler and about
adjustments to the idler.
NOTICE
Dealer Service Tool Catalog for tools and supplies
products.
mandates.
If the engine does not start, air may be trapped in the
fuel lines to the engine. Use the following procedure
in order to purge air from the fuel lines.
Electric Fuel Priming Pump

The electric fuel priming pump is located in the
engine compartment on the left side of the machine.
i02572431
Fuel System - Prime

SMCS Code: 1258
Personal injury or death can result from a fire.

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.
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.
Illustration 174
g01141823
1. Move the switch for the electric fuel priming pump

to the ON position. Allow the fuel priming pump to
run for several seconds.
2. Return the switch for the fuel priming pump to the
OFF position.
3. Start the engine. If you cannot start the engine,
the engine needs more priming. If the engine
continues to misfire or to smoke, more priming is
necessary.
Note: The electric fuel priming pump will only operate
if the engine start switch key is in the OFF position.
Shut off the engine before any additional priming.
4. Run the engine at the LOW IDLE position until the
engine runs smoothly.
120
Maintenance Section
Fuel System Secondary Filter - Replace
SEBU7925-08
Note: Do not activate the priming pump while you

crank the engine.
i02398364
Fuel System Secondary Filter Replace

SMCS Code: 1261-510-SE
Personal injury or death can result from a fire.

NOTICE
Illustration 175
g01141950
1. Turn the red handle of the fuel shutoff valve

clockwise in order to shut off the fuel supply. The
fuel shutoff valve is located at the rear of the
machine under the fuel tank.
2. Open the engine access door on the left side of
the machine. The secondary fuel filter is mounted
on the left side of the engine behind the primary
fuel filter.

products.
mandates.
Illustration 176
NOTICE
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
system parts.
Before you replace the secondary fuel filter element,
replace the primary fuel filter element.
g01141951
Front view
3. Remove the secondary fuel filter. Drain the fuel

into a suitable container.
Note: Discard any drained fluids according to local
regulations. Discard the fuel filter properly.
4. Clean the filter base. Make sure that all of the old
seal is removed.
5. Coat the seal of the new high efficiency fuel filter
with clean diesel fuel.
6. Install the new fuel filter by hand. When the
seal contacts the base, tighten the filter for an
additional 3/4 turn.
SEBU7925-08
121
Maintenance Section
Fuel System Water Separator - Drain
Rotation index marks are positioned on the filter

at 90 degree intervals. Use these rotation index
marks as a guide when you tighten the filter.
7. Open the fuel shutoff valve. Refer to illustration
175.
8. Prime the fuel system. See the Topic Fuel System
- Prime in this manual.
i02009564
Fuel System Water Separator

- Drain
SMCS Code: 1263-543
Illustration 177
g00104007
(1) Element
(2) Bowl
(3) Drain
Bowl (2) should be monitored daily for signs of water.

If water is present, drain the water from the bowl.
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
1. Open drain (3). The drain is a self-ventilated drain.

Catch the draining water in a suitable container.
Dispose of the water properly.
NOTICE
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tightened securely to help prevent air from entering the fuel
system.

products.
mandates.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over disconnected fuel system component.
2. Close drain (3).
i02281652
Fuel System Water Separator

Element - Replace
SMCS Code: 1263-510-FQ
Personal injury or death may result from failure to

adhere to the following procedures.
122
Maintenance Section
Fuel System Water Separator Element - Replace
SEBU7925-08
NOTICE
Do not fill fuel filter with fuel before installing the fuel
filter. Contaminated fuel causes accelerated wear to
fuel system parts.
NOTICE
products.
mandates.
Illustration 179
g01141926
3. In order to drain primary filter (1), open drain

valve (3) on water separator bowl (2). The water
separator bowl is under primary filter (1). Catch
the fuel in a suitable container.
Note: Discard any drained fluids according to local
regulations.
4. Remove primary filter (1) and water separator
bowl (2).
5. Remove water separator bowl (2) from the primary
filter element (1).
6. Wash water separator bowl (2) in a clean
nonflammable solvent. Use pressure air to dry
water separator bowl (2).
7. Install the clean water separator bowl onto a new
primary filter element.
Illustration 178
g01141906
1. The fuel shutoff valve is located at the rear of the

machine under the fuel tank. Turn the red handle
of the fuel shutoff valve in order to shut off the
fuel supply.
2. Remove the access cover on the left side of the
engine compartment.
8. Wash the filter mounting base in clean,

nonflammable solvent. Make sure that all of the
old seal is removed.
9. Coat the seal of the new filter element with clean
diesel fuel.
10. Install the new filter element by hand. When the
seal contacts the base, tighten the filter element
for an additional 3/4 turn.
Rotation index marks are positioned on the filter
elements at 90 degree intervals. Use these
rotation index marks as a guide when you tighten
the filter.
11. Open the fuel shutoff valve.
12. Prime the fuel system, if the machine is equipped
with a priming pump.
Refer to the Operation and Maintenance Manual,
Fuel System - Prime for the proper procedure.
SEBU7925-08
123
Maintenance Section
Fuel Tank Cap Filter and Strainer - Replace/Clean
5. Inspect the tank cap seal. If the seal is damaged,

replace the seal.
13. Install the access cover.

i02281929
Fuel Tank Cap Filter and

Strainer - Replace/Clean
6. Replace the filter assembly, the valve, the gaskets,

and the screws. Use a 9X-2205 Cap Filter Kit.
7. Install the strainer.
SMCS Code: 1273-070-STR; 1273-070-Z2
8. Install the fuel cap. Rotate the fuel cap clockwise

until three tabs (5) drop into the slots in the
adapter. Rotate lever (3) clockwise until the lever
stops. Lower lever (3) over locking tab (4).
i02281990
Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543-M&S
Illustration 180
g01141983
The fuel tank is located on the rear of the machine.

The filler cap is on the left side of the machine next to
the ROPS.
NOTICE
products.
mandates.
Illustration 181
g01141982
1. Lift lever (3) in order to remove the fuel tank filler

cap. Turn the lever counterclockwise until the
lever stops. Lift the cap straight up in order to
remove the cap.
2. Remove the fuel strainer from the filler neck.
3. In order to replace the filter assembly, remove two
screws that secure filter assembly (2) to the fuel
cap. Remove filter assembly (2), valve (1), and
the gaskets.
4. Wash the cap and the strainer in a clean,
nonflammable solvent.
Illustration 182
g01141998
The drain valve is under the fuel tank at the rear of

the machine.
1. Open the drain valve. Allow the water and the
sediment to drain into a suitable container.
2. Close the drain valve.
124
Maintenance Section
Fuses and Circuit Breakers - Replace/Reset
SEBU7925-08
i02281991
Fuses and Circuit Breakers Replace/Reset

SMCS Code: 1417-510; 1420-529; 1420
Fuses Fuses protect the electrical
system from damage that is caused by
overloaded electrical circuits. Replace
a fuse if the element separates. If the fuse of
a particular electrical system requires frequent
replacement, check the electrical circuit. Repair the
electrical circuit, if necessary.
Illustration 184
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.
g01142009
Circuit breaker, cover, and line fuse
Fuses are located behind cover (25).

Line Fuse (27) 175 Amp
Fuses
Contact your Caterpillar dealer.
Illustration 183
g00984827
Raised cover (battery box)
Raise the battery box cover on the right side of

the machine. Open the access door to the circuit
breakers and the fuses.
Illustration 185
g01142008
Fuses
A film for the fuse panel is on the inside of the battery

box cover.
Wipers (1) 15 Amp
Accugrade 1 (2) 15 Amp
Monitoring System (3) 15 Amp
Accurgrade 2 (4) 10 Amp
Implement or Drive train (5) 15 Amp
Auxiliary Switch (6) 15 Amp
SEBU7925-08
Fuse for the ripper pin puller, for the seat, and for
the winch (7) 10 Amp
Floodlights on Fender (8) 15 Amp
Flood Lights (Rear) (9) 15 Amp
Switching Type Converter (10) 10 Amp
Refrigerant Condenser (1) (ROPS) (11) 15 Amp
Refrigerant Condenser (2) (ROPS) (12) 15 Amp
Forward Horn (13) 15 Amp
Ignition Key (14) 15 Amp
Service Brake (15) 15 Amp
Flood Lights (Front) (16) 15 Amp
Product Link (17) 15 Amp
Converter (18) 10 Amp
Machine ECM (19) 15 Amp
Unswitched Fuse (20) 15 Amp
Engine ECM (21) 15 Amp
24 Volt to 12 Volt Converter (22) 20 Amp
Spare (23) 15 Amp
Spare (24) 15 Amp
Circuit Breakers
Circuit Breaker/Reset Push in the
button in order to reset the circuit breaker.
If the electrical system is working properly,
the button will remain depressed.
Note: If the button does not remain depressed, check
the appropriate electrical circuit. Repair the electrical
circuit, if necessary.
Blower (26) Circuit Breaker
125
Maintenance Section
Hydraulic System Oil - Change
i02282123

SMCS Code: 5050-044
Note: The normal hydraulic oil change interval
is at every 2000 Service Hours or 1 Year. By
performing SOS oil analysis, the hydraulic
oil change interval may be extended to 4000
Service Hours or 1 Year. SOS oil analysis must
be performed at every 500 Service Hours or
3 Months in order to extend the hydraulic oil
change interval. The results from the SOS oil
analysis will determine if the hydraulic oil change
interval may be extended. If SOS oil analysis is
not available, the hydraulic oil change interval
must remain at every 2000 Service Hours or 1
Year . Refer to the Operation and Maintenance
Manual, Hydraulic System Oil Sample - Obtain.
Machines that are used in severe conditions are
not included in the 4000 hour maintenance interval.
Machines that are used in severe conditions must
use the interval in the Maintenance Interval Schedule.
Lubricants
Approved hydraulic oil must be used to obtain the
4000 hour hydraulic oil change. Refer to the list that
follows for approved oils.
Caterpillar Hydraulic Oils

Cat HYDO
TDTO
Hydraulic environmental ester synthetic (HEES)
MTO
Commercial Oils
Diesel engine oils (Heavy Duty) with a minimum
zinc content of 900 ppm can be used. Acceptable
commercial oils are identified by the American
Petroleum Institute trademark (API). Refer to the list
that follows for acceptable types of hydraulic oils.
CF
CF-4
CG-4
CH-4
126
Maintenance Section
SEBU7925-08
Note: Industrial hydraulic oils are not recommended

for the hydraulic systems of Caterpillar machines.
Industrial hydraulic oils are more likely to allow
corrosion and industrial hydraulic oils are more likely
to allow excessive wear.
Change the Hydraulic Oil
At operating temperature, the hydraulic tank is hot

and under pressure.
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact
skin.
Illustration 186
g01142101
Right side of cab
Remove the filler cap only when the engine is

stopped, and the filler cap is cool enough to
touch with your bare hand. Remove the filler cap
slowly in order to relieve pressure.
1. Remove hydraulic tank filler cap (1) slowly in order

to relieve any pressure.
NOTICE
3. Use a 126-7914 Oil Drain Coupling and attach a

1 inch hose. Make sure that enough of the swivel
hose bypasses the track assembly and fills into a
suitable container.

products.
5. Install the swivel hose into the drain plug opening.

mandates.
Operate the machine in order to warm the oil.
Park the machine on level ground. Lower the
bulldozer blade to the ground and apply slight
downward pressure. If equipped, lower the ripper to
the ground. Engage the parking brake and stop the
engine.
2. Wash the filler strainer and the filler cap in a clean

nonflammable solvent.
4. Remove oil drain plug (3) which is located under

the right fender of the machine.
6. Rotate the swivel hose clockwise in order to open

the internal drain valve. Allow the oil to drain into a
suitable container.
7. Remove the swivel hose. The internal drain valve
for the hydraulic tank will close.
Tighten the drain plug to a torque of 68 7 Nm
(50 5 lb ft).
9. Change the hydraulic system filter.
Manual, Hydraulic System Oil Filter - Replace.
10. Install the filler strainer.
11. Fill the hydraulic oil tank.
Manual, Lubricant Viscosities and Capacities
(Refill) for additional information.
12. Inspect the filler cap gasket. Replace the gasket if
damage or wear is evident.
13. Install the filler cap.
SEBU7925-08
127
Maintenance Section
Hydraulic System Oil Filter - Replace
14. Start the engine. Operate the engine for a few

minutes.
NOTICE
products.
mandates.
Illustration 187
g01142156
1. Lower the bulldozer and the ripper to the ground.
15. Maintain the oil level to the FULL mark in sight

gauge (2). Add oil, if necessary.
i02282242
Hydraulic System Oil Filter Replace

SMCS Code: 5068-510

and under pressure.
skin.
Illustration 188
g01142202
Right side of cab
2. Slowly remove hydraulic tank filler cap (2) in order

to relieve the system pressure.
3. Remove retaining nuts (1).
Note: Both the case drain filter and the implement
return filter are inside the hydraulic tank.
4. Remove the cover and remove the oil filter from
each housing. Perform the following steps for
each oil filter.
5. Remove the filter element. Properly dispose of the
filter element.
Apply a thin coat of oil to the seal on the new filter
element.
6. Install the filter element by hand. After the seal
contacts the base, tighten the filter element by an
additional 3/4 turn (270 degrees).
7. Remove the retainer ring from the oil filler tube.
8. Remove the strainer from the oil filler tube.
128
Maintenance Section
Hydraulic System Oil Level - Check
SEBU7925-08
9. Wash the screen in a clean nonflammable solvent.

10. Inspect the seal on the filler cap. Replace the seal
if the seal is worn or if the seal is damaged.
11. Install the strainer, the retainer ring, and the cap.
Illustration 190
g01142156
1. Maintain the oil level to the FULL mark in the

sight gauge. Check the oil level when the oil is
cold. Verify that the oil level is below the FULL
mark before you remove the filler cap.
Illustration 189
g01142156
12. Maintain the hydraulic oil to the FULL mark in

the sight gauge.
i02282312
Hydraulic System Oil Level Check

SMCS Code: 5056-535-FLV; 7479

and under pressure.
skin.
Lower the bulldozer and the ripper to the ground.
Place the ripper shanks in the vertical position.
Illustration 191
g01142266
2. If the hydraulic system requires additional

hydraulic oil, remove the filler cap slowly in order
to relieve any pressure. Add oil through the filler
tube.
3. Clean the filler cap and install the filler cap.
i02282329
Hydraulic System Oil Sample

- Obtain
SMCS Code: 5095-008
The hydraulic tank is on the right fender of the

machine.
skin.
SEBU7925-08
129
Maintenance Section
Lift Cylinder Yoke Bearings - Lubricate

NOTICE
products.
Reference: Refer to , Lubricant Viscosities in the

i02282411
Lift Cylinder Yoke Bearings Lubricate

SMCS Code: 5102-086-BD

mandates.
Obtain the hydraulic oil sample as close as possible
to the recommended sampling interval. The
recommended sampling interval is every 500 service
hours. In order to receive the full effect of SOS oil
analysis, you must establish a consistent trend of
data. In order to establish a pertinent history of data,
perform consistent oil samplings that are evenly
spaced.
If the machine is operated under a high load
and/or under high temperature conditions,
sample all fluids at the 250 hour interval.
Illustration 193
1. Open the access cover on the right side of the cab

that is in front of the hydraulic tank.
The grease fittings are on the left side of the radiator

guard and on the right side of the radiator guard.
Lubricate the bearings by applying grease to the
fittings. Use MPGM grease.
g01142312
i02106227
Oil Filter - Inspect

SMCS Code: 1318-507; 3067-507; 5068-507
Inspect a Used Filter for Debris
Illustration 192
g01142283
The hydraulic oil sampling valve is shown.

3. Use 8T-9190 Fluid Sampling Bottle (1) to obtain
the sample.
4. After you take a sample, remove the cap with the
probe from the bottle. Discard the cap with the
probe. Install the sealing cap that is provided with
8T-9190 Fluid Sampling Bottle (1).
Illustration 194
The element is shown with debris.
g00100013
130
Maintenance Section
Pivot Shaft Oil Level - Check
SEBU7925-08
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.
The oil plugs are located on both sides of the

machine on top of the track roller frame.
1. Remove the oil plug on one side of the machine.
Check the oil level. The oil level should be at the
bottom of the threaded hole.
2. If necessary, add oil in order to bring the oil level
up to the bottom of the threaded hole.
Manual, Lubricant Viscosities in this manual for
the correct viscosity grade.
3. Install the oil plug.
4. Repeat Steps 1 through 3 on the other side of
the machine.
i00058126
Radiator Core - Clean

SMCS Code: 1353-070; 1805; 1810
i02282444
Pivot Shaft Oil Level - Check


skin.
Illustration 196
g00100624
You can use compressed air, high pressure water,

or steam to remove dust and other debris from the
radiator core. However, the use of compressed air
is preferred.
See Special Publication, SEBD0518, Know Your
Cooling System for the complete procedure for
cleaning the radiator core.
Illustration 195
g01142333
SEBU7925-08
131
Maintenance Section
Radiator Pressure Cap - Clean/Replace
i02282497
i02282842
Radiator Pressure Cap Clean/Replace
Recoil Spring Compartment

Oil Level - Check
SMCS Code: 1353-070-Z2; 1353-510-Z2
SMCS Code: 4158-535
At operating temperature, the engine coolant is

hot and under pressure.
Steam can cause personal injury.

skin.
Check the coolant level only after the engine has

been stopped and the fill cap is cool enough to
touch with your bare hand.
Remove the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent personal
injury.
Illustration 198
g01142564
1. Remove all of the debris around the cover plate

on the top of the track roller frame.
2. Remove the cover plate for the oil filler. Observe
the level of the oil.
Illustration 197
g01142388
Front view
1. Open radiator cap access cover (1). Slowly

remove radiator cap (2) in order to relieve system
pressure.
2. Inspect the radiator cap for damage, for deposits,
or for foreign material. Clean the radiator cap
with a clean cloth. Replace the radiator cap if the
radiator cap is damaged.
3. Install the radiator cap.
Illustration 199
g01110810
3. Maintain the oil level above the top of the track

adjusting cylinder (1). Do not fill the oil above the
track adjustment valve (2).
4. Install the cover plate.
5. Repeat the procedure for the other recoil
compartment.
132
Maintenance Section
Refrigerant Dryer - Replace
SEBU7925-08
i02292541
Refrigerant Dryer - Replace

(If Equipped)
SMCS Code: 7322-510; 7322-535
Personal injury can result from contact with refrigerant.

Contact with refrigerant can cause frost bite. Keep
face and hands away to help prevent injury.
Illustration 200
Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.
g01147674
2. Open the lower access door that is located on the

left side of the machine.
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.
Note: The in-line dryer contains the orifice tube and
the desiccant that dries the liquid refrigerant.
1. Stop the engine. Allow the air conditioning system
to remain inactive for five minutes in order to
equalize the pressure.
Illustration 201
g01147675
3. Remove the bolt and the clip that retains the dryer.
The lines that connect to the dryer are equipped
with quick disconnects. Remove the dryer.
4. Install a new dryer.
5. Install the bolt and the clip.
6. Fasten the connections to the dryer.
7. Close the access door.
SEBU7925-08
133
Maintenance Section
Ripper Linkage and Cylinder Bearings - Lubricate
i00072976
Ripper Linkage and Cylinder

Bearings - Lubricate
2. If the ripper tip is worn, drive out the pin. Remove

the tip and the shank pin retainer.
3. Clean the shank pin retainer and the pin.
4. Install the new tip and the retainer.
SMCS Code: 6313-086-BD, L4
5. Install the pin from the opposite side of the

retainer.
6. If the shank protector is worn, drive out the pins.
Remove the shank protector.
7. Clean the pin retainers and the pins.
8. Install the new shank protector and the retainers.
9. Install the pins from the opposite side of the
retainer.
10. Raise the ripper and remove the blocking.
Illustration 202
g00103773
11. Lower the ripper to the ground.
Lubricate eleven grease fittings.

i02282912
i00925689
Ripper Tip and Shank Protector

- Inspect/Replace
SMCS Code: 6808-040; 6808-510; 6810; 6812-040;
6812-510
If equipped:
Rollover Protective Structure

(ROPS) and Falling Object
Protective Structure (FOPS) Inspect
SMCS Code: 7323-040; 7325-040
Inspect the rollover protective structure/falling object
protective structure (ROPS/FOPS Structure) for
bolts that are loose or damaged. Replace any
damaged bolts and any missing bolts with original
replacement parts only. Tighten the bolts to a torque
of 800 100 Nm (600 75 lb ft).
Note: Apply oil to all of the bolt threads that will be
used to install the ROPS or the FOPS before you
install the bolts. Improper bolt torque can result if you
do not apply oil to the threads.
Illustration 203
g00550432
When the ripper tip is worn close to the shank,

replace the ripper tip. When the shank protector is
worn close to the shank, replace the shank protector.
If the tip is too blunt, the tip will not penetrate properly.
1. Raise the ripper. Place blocking under the ripper.
Lower the ripper onto the blocking. The ripper
should be high enough so that the ripper tip or the
shank protector can be removed. Do not place the
ripper too high.
Do not weld reinforcement plates to the ROPS or the

FOPS in order to straighten the ROPS or the FOPS.
Do not weld reinforcement plates to the ROPS or the
FOPS in order to repair the ROPS or the FOPS.
If the ROPS or the FOPS has any cracks in the
welds, in the castings, or in any metal section, consult
your Caterpillar dealer for repairs.
134
Maintenance Section
Seat Belt - Inspect
SEBU7925-08
i02429589
i02429594
Seat Belt - Inspect
Seat Belt - Replace
SMCS Code: 7327-040; 7520
SMCS Code: 7327-510
Always check the condition of the seat belt and the

condition of the seat belt mounting hardware before
you operate the machine. Replace any parts that are
damaged or worn before you operate the machine.
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.
Illustration 204
g00932801
Typical example
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.
Illustration 205
(1)
(2)
(3)
(4)
g01152685
Date of installation (retractor)

Date of installation (buckle)
Date of manufacture (tag) (fully extended web)
Date 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.
i02285650
Torque Converter Scavenge

Screen - Clean
SMCS Code: 3101-070-MGS; 3105
When you change the transmission oil, clean the
torque converter scavenge screen.
1. Remove the bottom guard in order to gain access
to the torque converter.
Note: Drain all fluids into a suitable container.
SEBU7925-08
135
Maintenance Section
Track - Check/Adjust
i02283030
SMCS Code: 4170-036
Illustration 206
g01143801
Front view
2. Disconnect hose (1) from the torque converter

housing.
Illustration 208
g01142731
Check the track adjustment. Check the track for wear

and for excessive dirt buildup.
Personal injury or death can result from grease

under pressure.
Grease coming out of the relief valve under pressure can penetrate the body causing injury or
death.
Illustration 207
g00822757
3. Remove the torque converter scavenge screen

from the torque converter housing.
4. Wash the screen in a clean, nonflammable
solvent.
5. Install the screen in the torque converter housing.
6. Connect the hose to the torque converter housing.
7. Install the bottom guard.
Do not watch the relief valve to see if grease is escaping. Watch the track or track adjustment cylinder to see if the track is being loosened.
Loosen the relief valve one turn only.
If track does not loosen, close the relief valve and
contact your Caterpillar dealer.
1. Move the machine forward. Allow the machine
to coast to a stop without the use of the service
brakes. Adjust the tracks while you are in the
machines typical operating conditions. If packing
conditions prevail on the workplace, the tracks
should be adjusted without removing the packed
material.
2. To measure the sag in the track, stretch a string
over the grousers that are between the sprocket
and the front idler. Take the measurement from
the string to the top of the grouser at the maximum
measurement. Dimension (A) is the maximum
distance between the string and the grouser.
136
Maintenance Section
SEBU7925-08
NOTICE
Do not attempt to tighten track when dimension (1) is
150 mm (5.9 inch) or more.
Contact your Caterpillar dealer for track service or instructions.
1. Remove the access cover.
Illustration 209
g01109482
If a machine does not have carrier rollers, the sag in

the track is measured between the sprocket and the
front idler. The correct adjustment of dimension (A) is
115 10 mm (4.5 .4 inch).
Illustration 212
g01019116
2. Add multipurpose grease (MPGM) through

track adjustment valve (1). Add the MPGM until
dimension (A, B, C) is correct.
3. Operate the machine back and forth in order to
equalize the pressure. Allow the machine to coast
to a complete stop. Do not use the brakes.
4. Remeasure dimension (D).
Illustration 210
g01118207
If the machine is equipped with a carrier roller,

calculate the average of dimension (B) and dimension
(C). The correct average value is 55 10 mm
(2.2 0.4 inch).
Loose Track Adjustment

Manual, Front Idler Position - Check for additional
information on System One Undercarriage.
Tight Track Adjustment

1. Loosen relief valve (2) by one turn of 360 degrees.
Allow the grease to escape.
2. Close the relief valve. Tighten the valve to a torque
of 34 7 Nm (25 5 lb ft).
3. Add MPGM through track adjustment valve (1).
Add grease until dimension (A, B, C) is correct.
Illustration 211
g01019107
SEBU7925-08
137
Maintenance Section
Track Pins - Inspect
Bolt Torque for Track Shoes
i01967485
SystemOne Undercarriage
The track shoe bolts are 22.0 mm (0.87 inch).
The torque requirement for track shoe bolts is
500 70 Nm (370 50 lb ft). Tighten the bolts by an
additional turn of 120 degrees.
Track Roller Frame Guides Inspect

SMCS Code: 4177-040
Measure the rotational movement of the front roller
frame relative to the rear roller frame.
Conventional Undercarriage
The track shoe bolts are 19.0 mm (0.75 inch).
The torque requirement for track shoe bolts is
400 70 Nm (300 50 lb ft). Tighten the bolts by an
additional turn of 120 degrees. If you are using bolts
with a master link, tighten the bolts to a torque of
400 70 Nm (300 50 lb ft). Then, tighten the bolts
by an additional turn of 180 degrees.
i01989298
Track Pins - Inspect

SMCS Code: 4175-040-PN
Illustration 213
g01021588
Some components are removed for clarity.
Fingers can be burned from hot pins and bushings.

The pins and bushings in a dry joint can become
very hot. It is possible to burn the fingers if there
is more than brief contact with these components.
1. Raise the front of the machine with the hydraulics

of the dozer. Place a 100 mm (4 inch) block under
the outside edge of a track grouser. Place the
block near the track idler. Lower the machine onto
the block.
Use the recommendations in order to extend the life

of the undercarriage. Use the recommendations in
order to avoid excessive downtime.
1. During the machine operation, listen for unusual
squeaking and for unusual squealing. This can
indicate a dry joint.
2. Check the machine for dry joints weekly. Check
for dry joints immediately after machine operation.
After machine operation, lightly touch the end of
each track pin or bushing. Touch the track pin
or the track bushing with the back of your hand.
Make a mark on any dry track pin joint that is very
hot to the touch.
Consult your Caterpillar dealers Custom Track
Service expert if you detect dry joints or leaks. Your
Caterpillar dealers Custom Track Service expert can
perform track inspection.
Illustration 214
g01021579
2. Use a grease pencil to make a mark on the tubular

section of the front roller frame. Make a mark
on the rear of the roller frame. This mark should
correspond with the mark that is on the tubular
section.
138
Maintenance Section
Transmission Breather - Clean
Illustration 215
SEBU7925-08
g01021605
Some components are removed for clarity.
3. Raise the front of the machine with the hydraulics

of the dozer. Place the block under the inside edge
of the same track grouser. Lower the machine
onto the block.
Illustration 217
g00785460
If dimension (X) is less than 45.3 mm (1.78 inch),

replace the track roller frame guides. Consult your
Caterpillar dealer for information or for service.
i02400075
Transmission Breather - Clean

SMCS Code: 3030-070
1. Open the front access door on the right side of
the cab.
Illustration 216
g01021583
4. Put a mark on the tubular section of the front roller

frame. This mark should correspond with the mark
on the rear roller frame. Measure the distance
between the two marks on the front roller frame.
If the distance between the two marks is greater
than 4.5 mm (.18 inch), inspect the track roller frame
guides for wear.
Repeat the entire procedure for the other side of the
machine.
NOTICE
Never build up the track roller frame guides with hardface welding. This will cause serious wear damage to
the guide slots in the front track roller frame.
Illustration 218
g01198807
2. The transmission breather is located on the bulk

head bracket. The bulk head bracket holds the
ports for the power train. Unscrew and remove
transmission breather (1).
3. Clean the breather in clean, nonflammable
solvent.
4. Install the breather.
SEBU7925-08
139
Maintenance Section
Transmission Breather - Replace
i02403434
Transmission Breather Replace
1. Remove the cover from the rear of the

transmission. The scavenge screen is located
behind the cover.
SMCS Code: 3030-510-BRE
2. Wash the screen in a clean, nonflammable

solvent.
1. Open the front access door on the right side of

the cab.
3. Inspect the seal. If the seal is damaged, replace

the seal.
4. Install the screen and the cover.
i02400246
Transmission System Oil Change

SMCS Code: 3030; 3080-044
Illustration 219
g01198807
2. The transmission breather is located on the bulk

head bracket. The bulk head bracket holds the
ports for the power train. Unscrew and remove
transmission breather (1).
3. Install the new breather.
4. Close the front access door on the right side of
the cab.
i02713189
Transmission Scavenge
Screen - Clean
SMCS Code: 3030-070-MGS
When you change the transmission oil , clean the
scavenge screen.

and under pressure.
skin.
slowly to relieve pressure.
NOTICE
products.
mandates.
Drain The Oil

Operate the machine in order to warm the power
train oil. The machine must be level. Lower the
attachments with slight down pressure.
Illustration 220
g01147719
See the Topic Transmission System Oil Filter Replace in this manual for the procedure to change
the filters.
140
Maintenance Section
Transmission System Oil - Change
SEBU7925-08
Use a 126-7538 Nozzle if the machine is equipped

with the high speed oil change arrangement. The
high speed oil change arrangement removes oil from
the sump in the bevel gear case. The high speed oil
change arrangement does not remove oil from the
torque converter or from the transmission case.
Illustration 222
g01198905
2. Remove cap (1) from the transmission oil filler

tube.
Illustration 221
g01147719
3. Fill the bevel gear case with oil. See Topic Refill
Capacities in this manual.
1. Remove the plug from the drain in the bevel gear

case. Install a 4C-8563 Swivel into the valve.
Clamp a hose to the swivel. A 25.4 mm (1 inch)
pipe and hose can be used. Use a 25.4 mm
(1 inch) pipe with 1-11 1/2 NPTF threads. Do not
tighten the pipe.
2. Turn the swivel or pipe clockwise in order to open
the internal drain valve. Allow the oil to drain into a
suitable container.
3. Change the filter element. See the Topic
Transmission System Oil Filter-Replace in this
manual.
4. Remove the swivel or remove the pipe from the
drain in the bevel gear case. The drain valve will
close.
5. Clean the oil drain plug and install the oil drain
plug.
Fill with Oil

in front of the hydraulic tank.
Illustration 223
g01147802
(2) Warm oil

(3) Cold oil
4. Always measure the oil with the transmission

dipstick on the cap.
5. Maintain the oil level within the marks for the
operating range on the dipstick. The engine
should be running at low idle. The power train
should be at operating temperature. See the Topic
Transmission System Oil Level - Check in this
manual.
6. Clean the oil filler cap. Install the oil filler cap.
7. Close the access door.
SEBU7925-08
141
Maintenance Section
Transmission System Oil Filter - Replace
i02400260
Transmission System Oil Filter

- Replace
SMCS Code: 3067-510
3. Clean the transmission oil filter housing with a

clean cloth.
4. Inspect the seal. If the seal is damaged, replace
the seal.
5. Install the new filter element into the oil filter
housing. Then, install transmission oil filter
housing (1) into base (2).
Note: Lubricate the threads of the transmission oil

filter housing.

skin.
6. Fill the transmission system with oil. See

illustration 224.
NOTICE

Manual, Lubricant Viscosities in this manual for
the correct viscosity grade of oil.
7. Start the engine.

products.
mandates.
If the transmission oil filter indicator in the monitoring
panel comes on before 1000 hours, the filter should
be changed.
The transmission oil filter is located behind the front
access cover on the right side of the cab.
Illustration 225
g01142953
Full marks
(5) Warm oil
(6) Cold oil
8. Maintain the oil level to the FULL mark (5) on

the transmission dipstick (4). If necessary, add oil
through transmission filler tube (3).
9. Close the access cover (not shown).
Illustration 224
g01198916
1. Remove transmission oil filter housing (1) from

the transmission oil filter base (2).
2. Remove the transmission oil filter element and
properly dispose of the filter element.
142
Maintenance Section
Transmission System Oil Level - Check
SEBU7925-08
i02400304
Transmission System Oil Level

- Check
SMCS Code: 3080-535
4. Close the engine access cover.

i02400308
Transmission System Oil

Sample - Obtain
SMCS Code: 3030-008

skin.

skin.
NOTICE
Illustration 226
g01198905

in front of the hydraulic tank. Check transmission
dipstick (1) while the engine is operating at low
idle and while the oil is at operating temperature.
Maintain the oil between the ADD mark and the
FULL mark.
Note: When you are operating the machine on severe
slopes, the quantity of oil in the transmission can be
increased up to 10 percent. When you are operating
with the increased oil quantity, prolonged operation
in some machines can cause high transmission oil
temperatures. After the work on the severe slopes
has been completed, drain the excessive oil quantity
from the bevel gear case.
2. If necessary, add oil.
Manual, Lubricant Viscosities and Refill
Capacities in this manual.
3. Clean the filler cap. Install the filler cap.
Replace the filter element if the transmission oil
filter indicator comes on during operation.
Manual, Transmission System Oil Filter Replace in this manual.

products.
mandates.
Obtain the sample of the transmission oil as close
as possible to the recommended sampling interval.
The recommended sampling interval is every 500
service hours. In order to receive the full effect of
SOS oil analysis, you must establish a consistent
trend of data. In order to establish a pertinent history
of data, perform consistent oil samplings that are
evenly spaced.
If the machine is operated under high load and/or
under high temperature conditions, sample all
fluids at the 250 hour interval.
SEBU7925-08
143
Maintenance Section
Trunnion Bearing - Adjust
i01499083
Trunnion Bearing - Adjust

SMCS Code: 6063-025
Illustration 227
g01198946

in front of the hydraulic tank.
Illustration 229
g00666217
Adjust the trunnion bearings after the initial 100

hours.
1. Lower the bulldozer blade to the ground. Walk to
the left side of the machine.
2. Remove two nuts (3) from two bolts (1) on the
trunnion bearing.
3. Remove two bolts (1), bearing cap (2), and two
shim packs (A and B) as a unit.
Illustration 228
g01143656
The oil sampling valve for the power train is shown.

3. Use 8T-9190 Fluid Sampling Bottle (1) to obtain
a sample.
4. After you take a sample, remove the cap with the
probe from the bottle. Discard the cap with the
probe. Install the sealing cap that is provided with
8T-9190 Fluid Sampling Bottle (1).
Reference: Refer to , Lubricant Viscosities in the
4. Remove one shim from each shim pack (A and B).

5. Install two bolts (1), bearing cap (2), and two shim
packs (A and B).
6. Install two nuts (3) on two bolts (1).
7. Tighten two nuts (3) to a torque of 1050 150 Nm
(775 110 lb ft).
8. Repeat steps 2 through 7 on the right side of the
machine.
144
Maintenance Section
Winch Fairlead Rollers - Lubricate
SEBU7925-08
Procedure for Shimming
9. Tighten the bolts that are on the front bearing to a

torque of 430 60 Nm (320 45 lb ft).
10. The assembly should move freely on the trunnion.
The specified minimum tolerance is 0.25 mm
(0.010 inch).
Note: Removal of one or more shims after a short
period of time may be necessary. Wear can be
caused by normal variations of the surface or
variations in the thickness of the paint.
i02112864
Illustration 230
g00292740
Typical example
1. Remove all of the shims from push arm assembly

(1).
Winch Fairlead Rollers Lubricate

SMCS Code: 5163-086
If equipped:
2. Install assembly (1) and cap (2) on trunnion

assembly (3) without shims.
3. Tighten the bolts that are on cap (2) to a torque of
50 Nm (37 lb ft).
Maintain equal distance on both space (A) and
space (B) of cap (2). Observe spaces (A) and
(B) in order to determine the required number of
shims.
4. Loosen the bolts that are on cap (2). As needed,
insert shims into spaces (A) and (B). When
possible, use an equal number of shims for
spaces (A) and (B).
Note: The number of shims at space (A) must be
within one of the number of shims at space (B). For
example, if space (A) has eight shims, space (B)
must have seven, eight, or nine shims.
5. Add one additional shim to space (A). Add one
additional shim to space (B).
6. Tighten the bolts that are on cap (2) to a torque of
1050 150 Nm (775 110 lb ft).
7. The assembly should move freely on the trunnion.
The specified minimum tolerance is 0.25 mm
(0.010 inch).
Note: Removal of one or more shims after a short
period of time may be necessary. Wear can be
caused by normal variations of the surface or
variations in the thickness of the paint.
8. Perform Steps 1 through 5 on the front bearing.
Illustration 231
g01076211
Lubricate the five fittings. Use MPGM Grease.

i02112874
Winch Oil Level - Check

If equipped:
SEBU7925-08
145
Maintenance Section
Winch Oil and Breather - Change/Clean
PA140VS
2. Remove drain plug (4) on the bottom of the winch.

Allow the oil to drain into a suitable container.
3. Inspect the plug seal. If necessary, replace the
plug seal.
5. Remove oil level plug (2).
6. Fill the oil compartment until oil is visible at the
bottom of the opening for the oil level plug.
See Operation and Maintenance Manual, Refill
Capacities.
Illustration 232
g01076215
1. Remove oil level plug (2) in order to check the oil

level. The oil level should be maintained to the
bottom of the level plug hole.
2. If necessary, remove oil filler plug (1) and add oil.
Check for oil leaks around the covers and around
the hoses. Repair any oil leaks.
i02283892
Winch Oil and Breather Change/Clean

(If Equipped)
Note: Use sight glass (3) on the other side of the

winch in order to check the oil level. The oil level
should be maintained with the sight glass.
7. Clean the vent plug that is in the filler plug. Use a
clean nonflammable solvent.
8. Clean the filler plug and install the filler plug.
9. Run the engine at low idle. Maintain the oil level
so that the oil level is visible at the bottom of the
opening for the oil level plug.
10. Install the oil check plug.
i02659765
Winch Wire Rope - Install

(If Equipped)
SMCS Code: 5163-044
SMCS Code: 5163-012

skin.
Do not operate or work on this equipment unless

you have read and understand the instructions
and warnings in the Operation and Maintenance
Manual. Failure to follow the instructions or heed
the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.
Personal injury or death can result from worn wire

rope cable.
Worn or frayed cable could break causing injury.
Check the wire rope cable. If cable is worn or is
frayed install a new cable.
Illustration 233
g01143124
146
Maintenance Section
Window Washer Reservoir - Fill
SEBU7925-08
i02284183
Wear leather gloves when handling the winch cable.

NOTICE
Unroll the wire rope cable from the spool. Never lift the
wire rope off the spool in coils.
NOTICE
Use the correct size ferrule for the winch cable in order
to attach the winch cable to the load drum. Never use
a knot in order to secure the winch cable to the load
drum.
Window Washer Reservoir Fill

SMCS Code: 7306-544
NOTICE
When operating in freezing temperatures, use
Caterpillar or any commercially available nonfreezing
window washer solvent.
The cable is attached to the drum on the winch with

a cable ferrule. The ferrule is placed into a socket
on the drum.
Use the following table to order the cable.
Table 17
Wire Rope
Wire Rope
Diameter
Recommended
Ferrule
Holding Capacity
25 mm (1 inch)
J-8
91 m (300 ft)
29 mm
(1.13 inch)
J-9
84 m (276 ft)
32 mm
(1.25 inch)
J-10
59 m (193 ft)
1. Put the cable in a straight line behind the tractor.
Illustration 235
g01143289
Windshield Washer Washer fluid bottle

(3) is on the left side of the machine in a
compartment between battery box (1) and
fuel tank (2). Open the access cover. Remove the
fluid bottle cap in order to fill the washer fluid bottle.
i02284211
Window Wipers Inspect/Replace

(If Equipped)
SMCS Code: 7305-040; 7305-510
1. Inspect front window wiper blade (1), the left
window wiper blade (5), and right window wiper
blade (6).
Illustration 234
1. Install the ferrule end into the socket .

2. Reel in the cable.
g00550538
SEBU7925-08
147
Maintenance Section
Windows - Clean
Illustration 237
g01143477
Rear window
1. Lift latch (1) in order to slide the small window.

Squeeze latch (2) in order to move the window
from the CLOSED position.
Illustration 236
g01143314
2. Open up small window (2).

3. Start rear wiper (3) and stop the wiper in the
leftmost position (4). Inspect the rear window
wiper blade or replace the wiper blade from the
inside of the cab only.
4. Replace any wiper blades that are damaged or
worn. Replace any wiper blades that streak the
window.
2. Move handle stop (3) to the UP position. To move

the handle stop to the UP position, lift the handle
and rotate the handle simultaneously. Rotate the
handle until the handle is vertical.
3. Move the small section of the window to opening
(4) in the upper window channel.
4. Tilt the top of the window toward the inside of the
cab. Remove the window.
5. Stay inside the cab in order to clean the outside
of the rear window.
i02284774
Windows - Clean
SMCS Code: 7310-070; 7340-070
If equipped:
Use commercially available window cleaning
solutions to clean the windows.
To clean the outside of the rear window from the
inside of the cab, remove the sliding section of the
rear window. Use the following procedure in order to
remove the sliding section of the rear window.
6. After cleaning, install the sliding section of the rear

window.

Safety CAT Intervalos de Mantenimientos

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Safety CAT Intervalos de Mantenimientos

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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 100 Service Hours

Every 250 Service Hours

Every 250 Service Hours or Monthly

Initial 500 Service Hours

Every 500 Service Hours

Every 500 Service Hours or 3 Months

Initial 1000 Service Hours

Every 1000 Service Hours or 6 Months

Every 2000 Service Hours or 1 Year

Every 3 Years After Date of Installation or

Every 6000 Service Hours or 3 Years

Every 6000 Service Hours or 4 Years

Every 12 000 Service Hours or 6 Years

Angle Blade Manual Tilt Brace

Lubricate the two fittings. Use Multipurpose Lithium

Backup Alarm - Test

1. Open the battery access covers. The battery

The backup alarm is on the rear of the machine.

Alternator and Water Pump Belt

1. Loosen bolts (1).

Fan Drive Belt

1. Loosen bolts (1).

3. Tighten bolts (1).

1. Loosen bolts (1).

2. Turn adjusting nuts (2) until the correct belt

ON The engine start switch key (1) must

4. Close the access doors.

Turn the engine start key to the ON position. The

Note: Use the same procedure in order to replace

The indicator lights on the top portion of the

Note: If new belts are installed, check the belt

The action light comes on briefly.

Brakes, Indicators and Gauges

CMS Functional Test

instrument panel come on briefly.

The auxiliary action light comes on briefly.

The action alarm sounds briefly.

If the system functions properly, start the engine. If

The indicator lights on the top portion or the bottom

The action light does not come on.

Total Service Hours

The battery disconnect switch must be ON in order

Service hours in forward speed range

Braking System (Test)

8. Reduce the engine speed to LOW IDLE. Engage

If the machine moves during the test, reduce the

9. Make any necessary repairs before you operate

If the machine moved while testing the brakes,

Note: The machine is capable of driving through

1. Start the engine.

Lubricate the Power Angle Tilt Blade at every 250

4. Lubricate the trunnion bearing (1 point).

Cab Filter (Fresh Air) Clean/Inspect/Replace

Cab Filter (Recirculation) Clean/Inspect/Replace

SMCS Code: 7342-040; 7342-070-FI; 7342-070;

SMCS Code: 7342-040; 7342-070; 7342-510

1. Remove filter cover (1) and filter element (2). The

1. Remove the filter element that is positioned in the