Kebu6860-10 M

2010 Caterpillar
All Rights Reserved
MAINTENANCE INTERVALS
Operation and Maintenance
Manual Excerpt
KEBU6860-10
June 2003
Operation and
Maintenance
Manual
CP-563C and CS-563C Vibratory
Compactors
4KN1-Up (Machine)
4LN1-Up (Machine)
5JN1-Up (Machine)
5KN1-Up (Machine)
57
Maintenance Section
Maintenance Interval Schedule
i01924285
SMCS Code: 1000; 7000
When Required
Battery - Recycle .................................................. 61
Cab Air Filter - Clean/Replace .............................. 62
Circuit Breakers - Reset ........................................ 63
Cutting Edges (Leveling Blade) - Inspect/
Replace ............................................................... 69
Drum Cooling Oil - Change ................................... 70
Drum Scrapers - Inspect/Adjust/Replace .............. 70
Engine Air Filter Primary Element -
Clean/Replace .................................................... 74
Engine Air Filter Secondary Element - Replace ... 76
Engine Air Precleaner - Clean .............................. 77
Fuel System - Prime ............................................. 86
Fuel System Water Separator - Drain ................... 89
Fuses - Replace .................................................... 90
Oil Filter - Inspect .................................................. 95
Wheel Nuts - Tighten .......................................... 100
Window Washer Reservoir - Fill .......................... 100
Window Wiper - Inspect/Replace ........................ 100
Every 10 Service Hours or Daily
Backup Alarm - Test .............................................. 60
Cooling System Coolant Level - Check ................ 67
Engine Air Filter Service Indicator - Inspect .......... 76
Engine Oil Level - Check ...................................... 78
Hydraulic System Oil Level - Check ...................... 93
Indicators and Gauges - Test ................................ 94
Neutral Start Switch - Test .................................... 95
Radiator Core - Clean ........................................... 96
Seat Belt - Inspect ................................................ 97
Steering Cylinder Ends - Lubricate ....................... 98
Windows - Clean ................................................. 100
Every 50 Service Hours or Weekly
Fuel Tank Water and Sediment - Drain ................. 90
Tire Inflation - Check ............................................. 98
Initial 250 Service Hours
Axle Oil (Rear) - Change ...................................... 59
Hydraulic System Oil Filter - Replace ................... 92
Every 250 Service Hours or 3 Months
Articulating and Oscillating Bearings - Lubricate .. 59
Axle Oil Level (Rear) - Check ............................... 60
Belts - Inspect/Adjust/Replace .............................. 61
Engine Oil Sample - Obtain .................................. 79
Engine Oil and Filter - Change ............................. 80
Final Drive Planetary (Axle) Oil Level - Check ...... 84
Final Drive Planetary (Drum) Oil - Check ............. 85
Fuel System Secondary Filter - Replace .............. 88
Vibratory Support Oil Level - Check ..................... 99
Initial 500 Hours (for New Systems, Refilled
Systems, and Converted Systems)
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 66
Obtain ................................................................. 66
Axle Oil Sample - Obtain ...................................... 60
Final Drive Planetary (Drum) Oil Sample -
Obtain ................................................................. 85
Fuel System Primary Filter - Replace ................... 86
Fuel System Secondary Filter - Replace .............. 87
Hydraulic System Oil Sample - Obtain ................. 93
Vibratory Support Oil Sample - Obtain ................. 99
Every 1000 Service Hours or 1 Year
Axle Oil (Rear) - Change ...................................... 59
Battery - Clean/Check ........................................... 61
Battery or Battery Cable - Inspect/Replace .......... 61
Cooling System Pressure Cap - Clean/Replace ... 67
Engine Crankcase Breather - Clean ..................... 77
Engine Valve Rotators - Inspect ............................ 82
Final Drive Planetary (Axle) Oil - Change ............. 83
Final Drive Planetary (Axle) Oil Sample - Obtain .. 84
Final Drive Planetary (Drum) Oil - Change ........... 84
Fuel Tank Cap Filter and Strainer -
Replace/Clean .................................................... 89
Hydraulic System Oil - Change ............................. 91
Hydraulic System Oil Filter - Replace ................... 92
Hydraulic Tank Strainer - Clean ............................ 93
Hydraulic Tank Vent - Replace .............................. 94
Propel Pump Linkage Rod - Lubricate .................. 96
Rollover Protective Structure (ROPS) - Inspect .... 97
Steering Pivot Clearance - Adjust ......................... 98
Vibratory Support Oil - Change ............................ 98
Every 2000 Service Hours or 1 Year
Engine Mounts - Inspect ....................................... 78
Every 2000 Service Hours or 2 Years
Crankshaft Vibration Damper - Inspect ................. 69
Engine Governor Oil Supply Screen -
Clean/Inspect/Replace ........................................ 77
Engine Valve Lash - Check ................................... 82
Fuel Injection Timing - Check ............................... 86
Every Year
Obtain ................................................................. 66
58
Maintenance Section
Cooling System Water Temperature Regulator -
Replace ............................................................... 68
Engine Water Pump - Inspect ............................... 83
Every 3 Years After Date of Installation or
Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................... 97
Cooling System Coolant Extender (ELC) - Add .... 65
Eccentric Weight Housing Oil - Change ............... 71
Cooling System Coolant (ELC) - Change ............. 63
59
Maintenance Section
Articulating and Oscillating Bearings - Lubricate
i01607989
Articulating and Oscillating
Bearings - Lubricate
SMCS Code: 7051-086-BD; 7057-086-BD;
7113-086-BD
g00384917
Illustration 95
Note: Wipe all of the fittings before lubricating the
bearing.
There are two fittings for the articulating bearing.
The fittings are located on the rear frame above the
pivot housing and below the pivot housing.
g00383920
Illustration 96
Note: Wipe all fittings before lubricating the
bearings.
There are two grease fittings for the oscillating
bearings. There is one fitting for the front bearing
and one fitting for the rear bearing. Both grease
fittings are located on the left side of the pivot
housing.
Note: The fitting for the front bearing is located at
the top of the plate on some machines.
i00780306
Axle Oil (Rear) - Change
SMCS Code: 3260-044
g00360312
Illustration 97
1. Remove the differential drain plug (1). The plug
is located at the bottom of the differential case.
Note: Drain the oil into a suitable container. Dispose
of the used oil in an appropriate manner.
g00360313
Illustration 98
2. Remove the differential level/fill plug (2). The
differential level/fill plug is located on the front
side of the axle.
3. Clean the drain plug (1) and install the drain
plug (1). Add the proper oil to the differential.
Maintain the level of the oil to the bottom of the
hole for the differential level/fill plug. Refer to the
Operation and Maintenance Manual, Lubricant
Viscosities and Refill Capacities section for
more information.
4. Clean the filler plug. Install the filler plug.
60
Maintenance Section
Axle Oil Level (Rear) - Check
i00801359
Axle Oil Level (Rear) - Check
SMCS Code: 3260-535-FLV
g00378132
Illustration 99
Note: The differential level/fill plug is located on the
front side of the rear axle.
1. Remove the level/fill plug. Maintain the oil level
to the bottom of the level/fill plug opening. If
necessary, add oil.
2. Clean the level/fill plug. Install the level/fill plug.
i00803323
Axle Oil Sample - Obtain
SMCS Code: 3260-008
g00360312
Illustration 100
The drain plug (1) is located on the bottom of the
differential.
Refer to Operation and Maintenance Manual, SOS
Oil Analysis and to Operation and Maintenance
Manual, Sampling Interval and Location of
Sampling Valve for information that pertains to
obtaining an oil sample from the axle.
i00780980
Backup Alarm - Test
SMCS Code: 7406-081
The backup alarm is located at the rear of the
machine.
g00343776
Illustration 101
Turn the engine start switch to the ON position in
order to perform the test.
Apply the parking brake. Move the propel control
lever to the REVERSE position.
The backup alarm should start to sound immediately.
The backup alarm will continue to sound until the
propel lever is moved to the STOP position or to
the FORWARD position.
g00100238
Illustration 102
In order to adjust the volume level, turn the
three-position selector switch. The switch is located
on the back of the backup alarm. When the machine
is shipped from the factory, the three-position
selector switch is set to the HIGH setting. The
three-position selector switch should remain at the
HIGH setting unless the job site requires a lower
volume level.
61
Maintenance Section
Battery - Clean/Check
i01613063
Battery - Clean/Check
SMCS Code: 1401-535
Note: The batteries that are supplied with the
machines are maintenance free batteries. You do
not need to check the level of the electrolyte in the
maintenance free batteries.
Tighten the battery retainers on both of the batteries.
Tighten the battery retainers at every 1000 hours.
Check the following items at every 1000 hours. If
necessary, check the following items more often.
Clean the top of the batteries with a clean cloth.
Clean the battery terminals. As needed, coat the

battery terminals with petroleum jelly.
i00059329
Battery - Recycle
SMCS Code: 1401-561
Always recycle a battery. Never discard a battery.
Always return used batteries to one of the following
locations:
A battery supplier
An authorized battery collection facility
Recycling facility
i01934013
Battery or Battery Cable -
Inspect/Replace
SMCS Code: 1401-040; 1401-510; 1402-040;
1402-510
1. Turn the engine start switch to the OFF position.
Turn all switches to the OFF position.
2. Turn the battery disconnect switch to the OFF
position. Remove the battery disconnect switch
key.
3. At the battery disconnect switch, disconnect the
negative battery cable that is connected to the
frame.
Note: Do not allow the disconnected battery cable
to contact the disconnect switch.
4. Disconnect the negative battery cable at the
battery.
5. Perform the necessary repairs. Replace the
cable or the battery, as needed.
6. Connect the negative battery cable at the battery.
7. Connect the battery cable at the battery
disconnect switch.
8. Install the battery disconnect switch key. Turn the
battery disconnect switch to the ON position.
i01608238
Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510
Your engine can be equipped with a water pump
belt, with a fan drive belt and with accessory drive
belts. Your engine can also be equipped with an
alternator belt. For maximum engine performance
and maximum utilization of your engine, inspect
the belts for wear and for cracking. Check the belt
tension. Adjust the belt tension in order to minimize
belt slippage. Belt slippage will decrease the belt
life. Belt slippage will also cause poor performance
of the alternator and of any driven equipment.
If new belts are installed, recheck the belt
adjustment after 30 minutes of operation. If two belts
or more are required for an application, replace the
belts in belt sets. If only one belt of a matched set
is replaced, the new belt will carry more load. This
is due to the fact that the older belts are stretched.
The additional load on the new belt could cause the
new belt to break.
g00385695
Illustration 103
Open the access cover on the left side of the
machine.
62
Maintenance Section
Cab Air Filter - Clean/Replace
Alternator Belt and Fan Drive Belt
g00385693
Illustration 104
1. To check the belt tension, apply 110 N (25 lb)
of force midway between the pulleys. Correctly
adjusted belts will deflect 13 to 19 mm
(1/2 to 3/4 inch).
2. To adjust the alternator belt and the fan drive
belt, loosen bracket bolt (1) and mounting bolt
(2) on the alternator bracket.
3. To achieve the correct adjustment, move the
alternator inward or move the alternator outward,
as required.
4. If necessary, use a pry bar in the square hole in
the alternator bracket.
5. Tighten mounting bolt (2) and bracket bolt (1).
Note: The alternator shaft nut must be tightened to
a torque of 50 5 Nm (37 4 lb ft).
6. If new belts are installed, check the belt
adjustment again after 30 minutes of engine
operation at the rated speed.
7. Check the position of the fan shroud. Adjust the
position of the fan shroud so that the fan will
not rub against the shroud. Maintain a 9.4 mm
(0.38 inch) clearance between the fan and the
shroud.
Water Pump Belt
1. To check the belt tension, apply 110 N (25 lb)
of force midway between the pulleys. Correctly
adjusted belts will deflect 13 to 19 mm
(1/2 to 3/4 inch).
g00385696
Illustration 105
2. To adjust the water pump drive belt, loosen
mounting bolt (1) and bracket bolt (3).
3. Move idler pulley (4) in order to achieve the
correct adjustment.
4. If necessary, use a pry bar in square hole (2) in
the mounting bracket.
5. Tighten mounting bolt (1) and bracket bolt (3).
6. If a new belt is installed, run the engine at rated
speed for thirty minutes. Check the bolt torque.
Readjust the belt, if necessary.
i00782049
Cab Air Filter - Clean/Replace
SMCS Code: 7342-070; 7342-510
g00361472
Illustration 106
1. Open the filter cover.
2. Clean the filter, or replace the filter.
63
Maintenance Section
Circuit Breakers - Reset
i00782066
Circuit Breakers - Reset
SMCS Code: 1420-529
Circuit Breaker/Reset Push in the button
in order to reset the circuit breaker. If the
electrical system is functioning properly,
the button will remain depressed. If the button
does not remain depressed, check the appropriate
electrical circuit. Repair the electrical circuit, if
necessary.
g00361734
Illustration 107
This circuit breaker is designed to protect the
alternator. For example, if the batteries are installed
with reversed polarity, the circuit breaker would
prevent the alternator from damaging the rectifier.
The circuit breaker has a capacity of 60 Amp.
i01608371
Cooling System Coolant (ELC)
- Change
SMCS Code: 1395-044-NL
Personal injury can result from hot coolant, steam
and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
NOTICE
Do not change the coolant until you read and under-
stand the material in the Cooling System Specifica-
tions section.
64
Maintenance Section
Cooling System Coolant (ELC) - Change
NOTICE
Mixing Extended Life Coolant (ELC) with other prod-
ucts reduces the effectiveness of the coolant and
shortens coolant life. Use only Caterpillar prod-
ucts or commercial products that have passed the
Caterpillar EC-1 specifications for premixed or con-
centrate coolants. Use only Caterpillar Extender with
Caterpillar ELC. Failure to follow these recommenda-
tions could result in the damage to cooling systems
components.
If ELC cooling system contamination occurs, refer to
Operation and Maintenance, Extended Life Coolant
(ELC) under the topic ELC Cooling System Contam-
ination.
Drain the coolant whenever the coolant is dirty or
whenever foaming is observed.
g00361992
Illustration 108
1. Slowly loosen the radiator cap in order to relieve
the pressure. Slowly remove the radiator cap.
g00361993
Illustration 109
2. Open the radiator guard on the rear of the
machine. The drain valve is located on the
bottom corner of the radiator. Open the drain
valve. Allow the coolant to drain into a suitable
container.
3. 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 in the solution should be
between 6 percent and 10 percent.
4. Start the engine. Run the engine for 90 minutes.
Stop the engine. Drain the cleaning solution into
a suitable container.
5. While the engine is stopped, flush the system
with water. Flush the system until the draining
water is transparent.
6. Close the drain valve.
7. Add the coolant solution. See the following
topics:
Special Publication, SEBU6250, Cooling

System Specifications
Operation and Maintenance Manual,

Capacities (Refill)
Note: If you are using Caterpillar antifreeze, do not
add the supplemental coolant additive at this time
and/or change the element at this time.
8. Start the engine. Run the engine without the
radiator cap until the thermostat opens and the
coolant level stabilizes.
9. Maintain the coolant level within 1 cm (0.5 inch)
of the bottom of the filler pipe.
10. Replace the radiator cap if the gasket is
damaged. Install the radiator cap.
11. Stop the engine.
12. Close and lock the access covers.
65
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
i01608429
Cooling System Coolant
Extender (ELC) - Add
SMCS Code: 1352-544-NL
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
Remove the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent personal
injury.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
When a Caterpillar Extended Life Coolant (ELC) is
used, an Extender must be added to the cooling
system. See the Cooling System Specifications
in the Operation and Maintenance Manual for all
cooling system requirements.
Use a 8T-5296 Coolant Test Kit to check the
concentration of the coolant.
For additional information about the addition of
Extender, see the Operation and Maintenance
Manual, Cooling System Specifications or consult
your Caterpillar dealer.
NOTICE
Mixing ELC with other products that do not meet
Caterpillar EC-1 specifications reduces the effective-
ness of the coolant and shortens coolant service life.
Use only Caterpillar products or commercial products
that have passed the Caterpillar EC-1 specification
for pre-mixed or concentrate coolants. Use only
Caterpillar Extender with Caterpillar ELC.
Failure to follow these recommendations can result in
shortened cooling system component life.
g00361992
Illustration 110
1. Slowly loosen the cooling system pressure cap
in order to relieve system pressure. Remove the
cooling system pressure cap.
2. If necessary, drain enough coolant from the
radiator in order to allow the addition of the
Extender.
3. Add the recommended amount of extender to
the coolant system. Refer to Operation and
Maintenance Manual, Extended Life Coolant
(ELC) for the proper amount of the ELC Extender
that needs to be added to the cooling system.
4. Maintain the coolant level 1 cm (0.5 inch) from
the bottom of the radiator filler pipe.
5. Inspect the gasket on the pressure cap, and
replace the filler cap if the gasket is damaged.
6. Install the cooling system pressure cap.
For additional information on the addition of
extender, see Special Publication, SEBU6250,
Coolant Recommendations or consult your
Caterpillar dealer.
66
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
i01933615
Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 7542
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
Note: Level 1 results may indicate a need for
Level 2 Analysis.
g00379726
Illustration 111
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.
Use the following guidelines for proper sampling
of the coolant:
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 mailing tube 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.

Submit the sample for Level 1 analysis.
For additional information about coolant analysis,
see Special Publication, SEBU6250, Caterpillar
Machine Fluids Recommendations or consult your
Caterpillar dealer.
i01933616
Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 7542
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
g00379726
Illustration 112
Obtain the sample of the coolant as close as
possible to the recommended sampling interval.
Supplies for collecting samples can be obtained
from your Caterpillar dealer.
Refer to Operation and Maintenance Manual,
Cooling System Coolant Sample (Level 1) - Obtain
for the guidelines for proper sampling of the coolant.
Submit the sample for Level 2 analysis.
67
Maintenance Section
Cooling System Coolant Level - Check
For additional information about coolant analysis,
see Special Publication, SEBU6250, Caterpillar
Machine Fluids Recommendations or consult your
Caterpillar dealer.
i01933901
Cooling System Coolant Level
- Check
SMCS Code: 1350-535-FLV; 1395-535-FLV
injury.
g00361992
Illustration 113
1. Slowly loosen the pressure cap in order to
release any pressure in the system. Slowly
remove the pressure cap.
2. Maintain the coolant level 1 cm (0.5 inch) from
the bottom of the filler pipe. If it is necessary to
add coolant daily, check the cooling system for
leaks. Repair the leaks as the leaks are found.
3. Inspect the gasket. Inspect the pressure cap.
Clean the pressure cap with a clean cloth.
Replace the cap if the gasket or the cap are
damaged.
4. Install the pressure cap.
i00803431
Cooling System Pressure Cap
- Clean/Replace
SMCS Code: 1382-070; 1382-510
Personal injury can result from hot coolant, steam
and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
g00379726
Illustration 114
1. The radiator cap is on the top right rear of the
machine.
2. Remove the radiator cap slowly in order to
relieve pressure.
3. Inspect the radiator cap for foreign material, for
deposits, and for damage. Clean the radiator
cap with a clean cloth. If the radiator cap is
damaged, replace the radiator cap.
4. Install the radiator cap.
68
Maintenance Section
Cooling System Water Temperature Regulator - Replace
i00803482
Cooling System Water
Temperature Regulator -
Replace
SMCS Code: 1355-510; 1393-010
injury.
Replace the water temperature regulator on a
regular basis in order to reduce the chance of
unscheduled downtime and of problems with the
cooling system.
The water temperature regulator should be replaced
after the cooling system has been cleaned. Replace
the water temperature regulator while the cooling
system is completely drained. Replace the water
temperature regulator while the cooling system
coolant is drained to a level below the water
temperature regulator housing.
NOTICE
Failure to replace the engines water temperature reg-
ulator on a regularly scheduled basis could cause se-
vere engine damage.
g00379726
Illustration 115
Note: If you are only replacing the water temperature
regulator, drain the cooling system coolant to a
level that is below the water temperature regulator
housing.
1. Remove the radiator cap in order to relieve the
pressure.
g00379833
Illustration 116
2. Loosen the hose clamp (4) and remove the hose
(1) from the water temperature regulator housing
(3).
3. Remove the bolts (2) from the water temperature
regulator housing (3) and remove the water
temperature regulator housing (3).
4. Remove the gasket and remove the water
temperature regulator from the water temperature
regulator housing. Make a note of the orientation
of the old regulator.
NOTICE
Former water temperature regulators may be used, if
they meet test specifications and are not damaged or
have excessive buildup or deposits.
NOTICE
Since Caterpillar engines incorporate a shunt design
cooling system, it is mandatory to always operate the
engine with a water temperature regulator.
Depending on load, failure to operate with a water tem-
perature regulator could result in either an overheating
or an overcooling condition.
NOTICE
If the water temperature regulator is installed incor-
rectly, it will cause the engine to overheat.
5. Install a new water temperature regulator. Orient
the regulator in the same manner as the old
regulator. Install a new gasket. Install the water
temperature regulator housing.
69
Maintenance Section
Crankshaft Vibration Damper - Inspect
6. Install the water temperature regulator housing
and the hose. Tighten the hose clamp.
7. Add the cooling system coolant. Maintain the
coolant level within 1 cm (0.5 inch) of the bottom
of the filler tube.
8. Inspect pressure cap and the gasket for damage.
Replace the pressure cap if the pressure cap or
the gasket are damaged.
9. Install the pressure cap.
i00803692
Crankshaft Vibration Damper
- Inspect
SMCS Code: 1205-040
g00380133
Illustration 117
g00380076
Illustration 118
Damage to the crankshaft vibration damper or
failure of the crankshaft vibration damper can
increase torsional vibrations. This can result in
damage to the crankshaft and to other engine
components. A deteriorating damper can cause
excessive gear train noise at variable points in the
speed range.
The damper is mounted to the crankshaft on the
front of the engine.
Visually inspect the crankshaft vibration damper for
damage.
Check the bolts for proper tightness. Refer to
the Operation and Maintenance Manual, Torque
Specifications.
i01608507
Cutting Edges (Leveling Blade)
- Inspect/Replace
SMCS Code: 6801-040; 6801-510
Personal injury or death can result if the levelling
blade is not blocked up. Block the levelling blade
before changing the cutting edge.
g00364692
Illustration 119
Replace the cutting edge if the cutting edge is
damaged. Replace the cutting edge if the cutting
edge is excessively worn.
1. Raise the leveling blade. Block the leveling blade
securely.
In order to change the cutting edge, block the
blade at a level that is just high enough to
change the cutting edge.
2. Remove the bolts. Remove the cutting edge.
3. Clean the contact surfaces.
4. If the opposite edge of the cutting edge is not
worn, use the opposite edge. If the opposite
edge is worn, replace the cutting edge.
70
Maintenance Section
Drum Cooling Oil - Change
5. Install the bolts. Tighten the bolts to the
torques that are specified in the Operation
and Maintenance Manual, Torques for Ground
Engaging Tool Bolts.
6. Raise the leveling blade. Remove the blocks.
7. Lower the leveling blade to the ground.
8. Check the bolts for proper torque after a few
hours of operation.
i00814127
Drum Cooling Oil - Change
SMCS Code: 6605-044-OC
g00393117
Illustration 120
Note: The following machines have a drain plug
that is located on the right side of the drum: (S/N:
4KN807-UP; 4LN807-UP; 5JN612-UP; 5KN240-UP).
The drum cooling oil requires service when
disassembly of the drum or assembly of the drum
is needed. Remove the drain plug in order to drain
the oil. Use the drain plug opening in order to fill
the cavity.
i00787371
Drum Scrapers -
Inspect/Adjust/Replace
SMCS Code: 6607-025; 6607-040; 6607-510
Smooth Drum Scrapers (If
Equipped)
Rubber Scrapers
There are two scrapers. One scraper is in front of
the drum. The second scraper is at the rear of the
drum.
Adjust
1. Inspect the scraper. Clean the scraper of dirt
and debris.
g00365672
Illustration 121
2. Loosen the bolts that are holding the rear rubber
scraper blade.
3. Loosen the nuts that hold the front rubber
scraper blade.
4. Adjust the rubber scraper blades to 7 mm
(0.25 inch) from the surface of the drum.
5. Tighten the bolts and tighten the nuts.
Replace the Rubber Scraper
1. Replace the rubber scrapers if the rubber
scrapers are excessively worn. Replace the
scrapers if the scrapers are damaged.
2. Loosen the bolts and the nuts that are holding
the rubber scraper.
3. Slide the rubber scraper out of the holder. Install
the new rubber scraper.
4. Adjust the rubber scraper blades to 7 mm
(0.25 inch) from the surface of the drum.
5. Tighten the bolts and tighten the nuts.
Steel Scrapers
drum.
Adjust
Adjust the steel scraper to 16 mm (0.625 inch) from
the drum surface.
71
Maintenance Section
Eccentric Weight Housing Oil - Change
Padded Drum Scraper Assembly (If
Equipped)
Adjust
drum.
1. Inspect the scraper. Clean the dirt and the debris
from the scraper.
g00365674
Illustration 122
2. Loosen the four nuts on each end of the scraper
assembly.
g00365675
Illustration 123
3. Slide the scraper toward the drum. Adjust the
tips so the tips are 19 mm (0.75 inch) from the
surface of the drum.
4. Tighten the nuts.
i01208037
Eccentric Weight Housing Oil
- Change
Change the Oil
1. Take an oil sample from each eccentric weight
housing. There is one eccentric weight housing
on each side of the drum. No flushing is
necessary, if the oil sample rating is equal or
lower than ISO 23/21. The flushing procedure
should be performed if an oil sample rating is
higher than ISO 23/21.
g00661120
Illustration 124
2. Rotate the drum until the welded item is at the
top of the drum. The drain plug is at the bottom
of the housing.
3. Place a suitable container under the drain plug.
Remove the drain plug. Drain the housing
completely. Repeat this step for both housings.
4. Clean the plug. Install the plug.
5. Rotate the drum until the welded item is at the
bottom of the drum.
g00612461
Illustration 125
72
Maintenance Section
6. Remove the filler plug.
g00661118
Illustration 126
7. Remove the level check plug. Fill the housing
with oil. Refer to the Operation and Maintenance
Manual, Lubrication Viscosities and Operation
and Maintenance Manual, Refill Capacities.
level check opening.
8. Clean the plugs. Install the plugs.
9. Repeat this procedure for the other eccentric
weight housing.
Flush the Housing
g00661129
Illustration 127
1. There are two eccentric weight housings. The
housings are on each side of the drum. Perform
the following procedure on each housing.
2. Drain the oil from the eccentric weight housings.
g00411939
Illustration 128
3. Pump 151 L (40 US gal) of a suitable hydraulic
oil into a 208 L (55 US gal) drum.
g00646305
Illustration 129
(1) 8C-6875 Connector
(2) 8B-5774 Reducer Bushing
(3) 9U-6989 Head
(4) 9U-6983 Filter Element
(5) 6V-3965 Nipple Assembly
(6) 8T-4834 Swivel Orifice Tee
(7) 127-8781 Filter Cart
(8) 2.4 m (8 ft) of 25 mm (1 inch) diameter hose.
(9) 3B-6498 Elbow
(10) 3L-7024 Street Elbow
(11) 127-0593 Connector
(12) 3B-7728 Elbow
(13) 3B-7265 Pipe Nipple
(14) 940 mm (37 inch) long, 25 mm (1 inch) diameter pipe with
a 45 angle cut at one end.
4. Use the 127-8781 Transfer Cart Group in order
to flush the oil in the 208 L (55 US gal) drum.
Filter the oil for 30 minutes. The particle count of
the clean oil must be a maximum of ISO 18/13.
73
Maintenance Section
g00411939
Illustration 130
5. Raise the machine. The drum and tires must
not be in contact with the ground or the floor.
Support the machine on stands.
g00412139
Illustration 131
6. Start the engine. Release the parking brake and
rotate the drum until the fill/drain plug is at the
top of the housing. Remove the plug. Install the
valve and fitting assembly that is appropriate for
your machine.
g00485100
Illustration 132
7. Assemble the 126-7187 Adapter (20) into
the male end of the 5R-3796 Quick Coupling
Assembly (19). Install the adapter into the hole
for the oil fill/drain plug. Assemble the 8T-0198
Seal Connector (18) onto the female end of the
quick coupler. Attach the female end of the quick
coupler to the transfer cart suction hose in order
to drain the flushing oil from the housing.
g00661111
Illustration 133
8. Rotate the drum until the fill/drain plug is at the
bottom. Put a mark on the surface of the drum at
the top of the drum. The mark will help identify
the position of the fill/drain plug.
g00412139
Illustration 134
9. Remove the level check plug. Connect the quick
coupler (19). Fill the housing with 22 L (6 US gal)
gallons of clean oil. Install the plug.
74
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
g00609614
Illustration 135
10. Run the first flush cycle.
a. Start the engine. Release the brake.
b. Set the travel speed control to low speed. In
order to rotate the drum, move the propel
control.
c. Set the vibratory amplitude control to the low
position.
d. Turn on the vibratory system. Run the vibratory
system for 5 seconds. Turn off the vibratory
system. Repeat the cycle for three minutes.
Note: For each cycle, do not run the vibratory
system more than 5 seconds.
e. Stop the drum. Position the drum in order to
drain the housings.
11. Install the transfer cart. Pump the oil out of the
housings. Cycle the oil through the filter for 30
minutes. Cycle the oil until the oil is cleaned to
a rating of ISO 18/13 or better.
12. Install the transfer cart to the housings. Pump
the oil into the housings. For the second cycle,
repeat steps 6 through 9. After the second cycle,
take an oil sample before filtering the oil. No
further flushing is necessary, if the oil sample
rating is equal or lower than ISO 19/16. Another
flushing is necessary, if the oil sample rating is
higher than ISO 19/16.
13. When the flushing is complete, rotate the drum
to the position in order to drain the housings.
Remove the valve and fitting assembly. Drain as
much of the oil as possible.
14. Rotate the drum until the fill/drain plug is at the
top. Remove the level check plug. Fill the drum
to the correct level. Refer to the Operation and
Maintenance Manual, Lubrication Specifications
and Refill Capacities.
Note: The new oil must have a oil sample rating that
is equal or lower than ISO 18/15.
i01822655
Engine Air Filter Primary
Element - Clean/Replace
SMCS Code: 1054-070-PY; 1054-510-PY
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.
Service the air cleaner filter element when the
yellow piston on the engine air filter service
indicator enters the red zone or the indicator
reads 63.5 cm (25 inch) of water. Refer to
Operation and Maintenance Manual, Engine Air
Filter Service Indicator - Inspect.
1. Open the access door on the left side of the
machine.
g00537958
Illustration 136
2. Squeeze the outlet tube slightly in order to purge
the dirt from the outlet tube.
g00101413
Illustration 137
75
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
3. Loosen the four cover latches and remove the
air cleaner cover.
g00101415
Illustration 138
4. Remove the primary filter element from the air
cleaner housing.
5. Clean the air cleaner cover and the inside of the
air cleaner housing.
6. Inspect the O-ring seal on the air cleaner cover.
Replace the O-ring seal if the O-ring seal is worn
or damaged.
NOTICE
Do not clean the filter elements by bumping or tapping
them. Do not use filter elements with damaged pleats,
gaskets or seals. Engine damage can result.
Make sure the cleaned filter elements are completely
dry before installing into the filter housing. Water re-
maining in the elements can cause false indications of
contamination in Scheduled Oil Sampling test results.
7. Clean the primary filter. Inspect the primary filter.
Primary filter elements can be cleaned with low
pressure air. Caterpillar does not recommend
cleaning the air filter.
Refer to Operation and Maintenance, General
Hazard Information before you use pressure air
in order to clean the primary filter element.
g00102970
Illustration 139
8. Direct air along the pleats inside the primary filter
element and outside the primary filter element.
Do not touch pleats with the air nozzle.
9. Inspect the primary filter element after the
element is clean. Do not use a primary filter
element with damaged pleats, damaged gaskets
or damaged seals.
10. Encase the clean primary filter element and
store the clean primary filter element in a clean,
dry place.
11. Install the clean primary filter.
12. Install the air cleaner cover and close the
latches securely.
g00101416
Illustration 140
Note: Install the air cleaner cover properly. The
arrows must point upward.
13. Change the filter if the exhaust smoke is still
black.
Note: Replace the primary filter if the primary filter
has been in service for one year.
14. Close the access door.
76
Maintenance Section
Engine Air Filter Secondary Element - Replace
i01822684
Engine Air Filter Secondary
Element - Replace
SMCS Code: 1054-510-SE
NOTICE
Always replace the secondary filter element. Never at-
tempt to reuse the secondary filter element by clean-
ing the element.
When the primary filter element is replaced, the sec-
ondary filter element should be replaced.
The secondary filter element should also be replaced
if the exhaust smoke is still black.
1. Open the access door on the front left side of
the machine.
2. See Operation and Maintenance Manual, Engine
Air Filter Primary Element - Clean/Replace.
Remove the air cleaner cover from the air cleaner
housing. Remove the primary filter element from
the air cleaner housing.
g00101451
Illustration 141
3. Remove the secondary filter element.
4. Cover the air inlet opening. Clean the inside of
the air cleaner housing.
5. Remove the cover from the air inlet opening.
6. Install the new secondary filter element.
7. Install the primary filter element.
8. Install the air cleaner cover and close the latches
securely.
i00788847
Engine Air Filter Service
Indicator - Inspect
SMCS Code: 7452-040
g00366677
Illustration 142
1. Open the engine compartment access door.
2. Start the engine.
3. Run the engine at high idle.
g00366972
Illustration 143
4. If the yellow piston in the engine air filter service
indicator enters the red zone, service the air
cleaner.
5. Stop the engine.
Note: See the Operation and Maintenance Manual,
Engine Air Filter Primary Element - Clean/Replace.
See the Operation and Maintenance Manual,
Engine Air Filter Secondary Element - Replace.
6. Close the engine access door.
77
Maintenance Section
Engine Air Precleaner - Clean
i00788900
Engine Air Precleaner - Clean
SMCS Code: 1055-070
g00367052
Illustration 144
1. Check the precleaner for accumulation of trash
and dirt.
2. Empty the bowl whenever the dirt is present in
the bowl.
3. Loosen the wing nut on the top of the precleaner.
Remove the wing nut and remove the bowl.
4. Empty the bowl and wash the bowl.
5. Install the bowl and the cap. Finger tighten the
wing nut. Do not use a tool to tighten the wing
nut.
i00788960
Engine Crankcase Breather -
Clean
SMCS Code: 1317-070
g00366677
Illustration 145
1. Open the access door on the right side of the
machine.
g00367132
Illustration 146
2. Loosen the hose clamp (2). Remove the hose
(3) from the breather.
3. Remove bolt (4). Remove the breather (4) and
the O-ring seal.
4. Wash the breather (4) in clean nonflammable
solvent. Dry the breather (4) with pressure air.
5. Install the O-ring seal. Install the clean breather.
6. Tighten the bolt (1) to a torque of 7 2 Nm
(5 1 lb ft).
7. Install the hose (3) onto the breather (4). Tighten
the hose clamp.
i00789000
Engine Governor Oil Supply
Screen - Clean/Inspect/Replace
SMCS Code: 1264-510-Z3; 1264-571-Z3;
1278-510-Z3; 1278-571-Z3
g00366677
Illustration 147
78
Maintenance Section
Engine Mounts - Inspect
machine.
g00270086
Illustration 148
2. Remove the oil supply tube (1) from the cylinder
head.
3. Remove the fitting (3) and the seal (2) from the
governor housing.
4. Use a 6 mm hexagon wrench in order to remove
the screen (4).
5. Wash the screen (4) in solvent in order to remove
any debris.
6. Inspect the screen (4) for damage. Replace
damaged parts.
7. Install the screen (4). Allow clearance for the
fitting (3).
8. Install the seal (2). Install the fitting (3). Install
the oil supply tube (1).
i00808262
Engine Mounts - Inspect
SMCS Code: 1152-040
g00383372
Illustration 149
Engine vibration can be caused by improper
mounting of the engine. Engine vibration can be
caused by loose engine mounts or deteriorated
engine mounts.
Inspect the engine mounts for deterioration.
Replace any engine mount that is deteriorated.
Inspect the engine mounts for correct bolt torque.
If the mounts are loose, torque the front engine
mount to 450 Nm (331 lb ft). Torque the rear mounts
to 220 Nm (162 lb ft).
i00789760
Engine Oil Level - Check
NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
Stop the engine in order to check the oil level. DO
NOT check the oil level when the engine is running.
Park the machine on a level surface.
79
Maintenance Section
Engine Oil Sample - Obtain
g00366677
Illustration 150
machine.
g00367853
Illustration 151
2. Remove the dipstick (1). Wipe the dipstick with a
clean cloth. Insert the dipstick (1). Remove the
dipstick and note the oil level. Insert the dipstick.
Note: Refer to the Operation and Maintenance
Manual, Lubricant Viscosities and Refill Capacities
for the correct amount of oil that is used when the
oil is changed. The correct amount of oil determines
the correct level of the oil in the FULL range on the
dipstick.
NOTICE
Do not overfill the crankcase. The oil level must not
reach the top of the FULL range mark or above the
FULL range mark.
g00367841
Illustration 152
3. Maintain the oil level on the dipstick between the
FULL RANGE mark and the ADD OIL mark .
Add oil if the oil level is too low.
Note: Operating your engine with the oil level above
the FULL mark in the FULL RANGE could cause
the crankshaft to dip into the oil. This could result
in excessively high operating temperatures. The
high operating temperatures could result in reduced
lubricating characteristics of the oil. This could
cause damage to the bearings and loss of engine
power.
4. Remove the oil filler plug (2).
5. Add the oil.
6. Clean the oil filler plug (2). Install the oil filler
plug (2).
i00790311
Engine Oil Sample - Obtain
SMCS Code: 1348-008
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
Obtain the Sample and the Analysis
In addition to a good preventive maintenance
program, Caterpillar recommends using SOS oil
analysis at regular scheduled intervals in order
to monitor the condition of the engine and the
maintenance requirements of the engine.
80
Maintenance Section
Engine Oil and Filter - Change
Each oil sample should be taken when the oil is
warm and when the oil is well mixed. The sample
should be taken at this time in order to ensure
that the sample is representative of the oil in the
crankcase.
Obtain the SOS Sample
Use one of the following methods in order to obtain
an SOS sample:
Use the oil sampling valve (if equipped).
Use a 1U-5718 Vacuum Pump or use an

equivalent pump that is inserted into the sump.
Caterpillar recommends using the sampling valve
(if equipped) in order to obtain oil samples. The
quality and the consistency of the samples is better
when the sampling valve is used. If the engine is
not equipped with a sampling valve, the use of a
1U-5718 Vacuum Pump is preferred.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
Refer to Special Publication, PEHP6001 for more
information on obtaining a good oil sample. Consult
your Caterpillar dealer for complete information and
assistance in establishing an SOS program for
your engine.
g00366677
Illustration 153
1. Open the engine access door on the right side
of the machine.
g00368232
Illustration 154
2. The oil sampling valve is on the right side of the
engine. The oil sampling valve is located above
the governor.
3. Open the sampling valve. Obtain an oil sample
in a suitable container and close the sampling
valve.
4. Seal the container and label the container. Send
the sample to your Caterpillar dealer for analysis.
5. Close the engine access door and secure the
door.
i00790346
SMCS Code: 1318-510
Run the engine in order to warm up the oil. Stop
the engine before draining the oil. When the oil is
warm the waste particles are suspended in the oil.
The waste particles will be removed when the oil
is drained.
As the oil cools, the waste particles settle to the
bottom of the oil pan. The waste particles will not
be removed if the oil is too cool.
The waste particles can recirculate through the
engine lubrication system if the recommended
procedure is not followed.
81
Maintenance Section
g00370306
Illustration 155
1. Open the engine access door on the left side of
the machine.
g00370307
Illustration 156
2. Place a suitable container under the drain valve.
Open the drain valve.
3. Allow the oil to drain completely.
g00370311
Illustration 157
5. Remove the filter element. Discard the used filter
element.
6. Clean the filter housing base. All of the old filter
seal must be removed from the filter housing
base.
7. Apply a thin coat of engine oil to the seal of the
new filter element.
8. Install the new filter by hand. When the gasket
contacts the filter base, turn the filter by
270 degrees more. This will tighten the filter
sufficiently.
Every new oil filter has rotation index marks that
are spaced at 90 degree increments. Use the
rotation index marks as a guide for tightening
the oil filter.
g00366677
Illustration 158
9. Open the engine access door on the right side
of the machine.
g00367853
Illustration 159
10. Remove the oil filler plug (2). Fill the crankcase
with new oil. See Operation and Maintenance
Manual, Refill Capacities. Clean the oil filler
cap and install the oil filler cap.
82
Maintenance Section
Engine Valve Lash - Check
NOTICE
Do not overfill to reach above or to the top of the FULL
RANGE on the dipstick.
Operating your engine when the oil level is above
the FULL mark in the FULL RANGE could cause the
crankshaft to dip into the oil. This could lead to ex-
cessively high oil temperatures, which can reduce the
lubricating characteristics of the oil, leading to bearing
damage, and could result in the loss of engine power.
g00367841
Illustration 160
11. Before starting the engine, check the oil level
on the dipstick. The oil level must be within the
FULL RANGE on the dipstick.
12. Start the engine. Run the engine for two minutes.
Inspect the machine for leaks. Stop the machine.
13. Wait for ten minutes in order to allow the oil
to drain back into the crankcase. Check the
oil level. Maintain the oil level within the FULL
RANGE on the dipstick.
14. Close the access doors and secure the access
doors.
i00687328
Engine Valve Lash - Check
SMCS Code: 1105-535
This maintenance is recommended by Caterpillar
as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
ment procedure.
Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life.
Ensure that the engine can not be started while
this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
to turn the flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before mea-
suring/adjusting valve lash clearance.
Ensure that the engine is stopped before measuring
the valve lash. To obtain an accurate measurement,
allow the valves to cool before this maintenance
is performed.
Refer to the Service Manual for more information.
i01597115
Engine Valve Rotators - Inspect
SMCS Code: 1109-040
When inspecting the valve rotators, protective
glasses or face shield and protective clothing
must be worn, to help prevent being burned by
hot oil or spray.
Engine valve rotators rotate the valves when the
engine runs. This helps to prevent deposits from
building up on the valves and the valve seats.
Perform the following steps after the engine valve
lash is set, but before the valve covers are installed:
1. Start the engine according to Operation
and Maintenance Manual, Engine Starting
(Operation Section) for the procedure.
2. Operate the engine at low idle.
83
Maintenance Section
Engine Water Pump - Inspect
3. Observe the top surface of each valve rotator.
The valve rotators should turn slightly when the
valves close.
NOTICE
A valve rotator which does not operate properly will
accelerate valve face wear and valve seat wear and
shorten valve life. If a damaged rotator is not replaced,
valve face guttering could result and cause pieces of
the valve to fall into the cylinder. This can cause piston
and cylinder head damage.
If a valve fails to rotate, consult your Caterpillar
dealer.
i00808554
Engine Water Pump - Inspect
SMCS Code: 1361-040
A water pump that has failed might cause severe
engine overheating. Severe engine overheating
could result in the following problems:
Cracks in the cylinder head
Piston seizure
Other potential engine damage

g00383772
Illustration 161
Visually inspect the water pump for leaks. If leaks
are found, all the seals must be replaced.
Note: See the Service Manual for your machine for
more information about this topic.
i01608624
Final Drive Planetary (Axle) Oil
- Change
g00451630
Illustration 162
1. Remove drain plug (2).
2. Drain the oil into a suitable container.
3. Clean the drain plug, and install the drain plug.
4. Remove level check/fill plug (1).
5. Add oil to the planetary. Fill the planetary to the
bottom of the level check/fill plug opening.
6. Refer to the Operation and Maintenance Manual,
Capacities (Refill), and Lubrication Viscosities.
7. Clean the level check/fill plug and install the level
check/fill plug.
84
Maintenance Section
Final Drive Planetary (Axle) Oil Level - Check
i01608878
Level - Check
g00451636
Illustration 163
1. In order to check the level of the oil in the
planetary, remove level check/fill plug (1).
level check/fill plug opening.
2. If necessary, add oil.
3. Clean the level check/fill plug and install the plug.
i01608923
Sample - Obtain
SMCS Code: 4050-008
g00451639
Illustration 164
Obtain the oil sample when you change the oil.
Refer to the Operation and Maintenance Manual,
SOS Oil Analysis. Refer to the Operation and
Maintenance Manual, Sampling Interval and
Location of Sampling Valve for information on
obtaining the oil sample from the planetary.
i01608930
Final Drive Planetary (Drum)
Oil - Change
SMCS Code: 4050-044-OC; 5655-044-OC
g00365384
Illustration 165
1. Rotate the drum until fill/drain plug (1) is located
at the bottom.
2. Remove fill/drain plug (1). Drain the oil into
a suitable container. Dispose of the oil in an
acceptable manner.
3. After the oil is drained, install fill/drain plug (1).
4. Rotate the drum until fill/drain plug (1) is located
at the top of the planetary and plug (2) is located
at the middle.
5. Refer to the Operation and Maintenance Manual,
Lubricant Viscosities and Capacities (Refill).
6. Fill the planetary until the oil is at the bottom of
the level check plug opening.(2).
7. Clean plugs (1) and (2). Install plugs (1) and (2).
85
Maintenance Section
Final Drive Planetary (Drum) Oil - Check
i01609277
Oil - Check
SMCS Code: 4050-535-FLV; 5655-535-FLV
g00365518
Illustration 166
The final drive planetary for the drum is located on
the left side of the drum.
g00365519
Illustration 167
1. Rotate the drum until plug (1) is located at the
90 degree position.
2. Remove the level check plug. Check the level of
the oil in the planetary. Maintain the level of the
oil at the bottom of the level check plug opening.
g00365520
Illustration 168
3. If the oil level is low, remove fill/drain plug (2).
4. In order to maintain the proper oil level, add oil.
5. Clean the plugs and install the plugs.
i01611048
Oil Sample - Obtain
SMCS Code: 4050-008; 5655-008
g00380212
Illustration 169
Refer to Operation and Maintenance Manual,
SOS Oil Analysis and refer to Operation and
Location of Sampling Valve for information that
pertains to obtaining an oil sample from the axle.
86
Maintenance Section
Fuel Injection Timing - Check
i00675887
Fuel Injection Timing - Check
SMCS Code: 1290-531-FT
A qualified mechanic should adjust the fuel injector
timing because special tools and training are
required.
Note: The correct fuel timing specification is
found on the Engine Information Plate. Fuel
timing specifications may vary for different engine
applications and/or for different power ratings.
i00793376
Fuel System - Prime
SMCS Code: 1250-548
g00366677
Illustration 170
machine.
g00370933
Illustration 171
2. Open the valve (2). Push the plunger (1) until the
fuel starts to come out of the valve.
3. Close the valve (2).
4. Push the plunger (1) for 10 additional strokes.
5. Start the engine. Check for leaks.
6. Close the engine access door.
i01611445
Fuel System Primary Filter -
Replace
SMCS Code: 1260-510
g00366677
Illustration 172
machine.
g00372736
Illustration 173
2. Turn valve (1) in a counterclockwise direction.
Drain the fuel into a suitable container.
3. Close valve (1).
4. Hold bowl (5) while you loosen collar (4). Remove
bowl (5) and collar (5).
87
Maintenance Section
Fuel System Secondary Filter - Replace
g00372835
Illustration 174
5. Loosen collar (2). Remove element (3). Discard
the element in a proper manner.
6. Clean the parts. Inspect the parts for damage.
Replace the damaged parts or replace the worn
parts.
7. Install a new element. Tighten collar (2).
8. Install bowl (5) and tighten collar (4).
9. Start the engine and check the fuel system for
leaks.
10. Close the access door and secure the access
door.
i01611470
Fuel System Secondary Filter -
Replace
g00366677
Illustration 175
1. Open the access cover on the right side of the
machine.
g00372052
Illustration 176
Note: You must drain secondary fuel filter element
(1) before the removal or the replacement of either
filter element.
2. Place a suitable container under valves (2)
and (4). Open valve (2) in order to drain upper
secondary fuel filter element (1). Immediately
open drain valve (4) after opening drain valve
(2). This sequence prevents an air lock in the
fuel system.
Note: Every new oil filter has rotation index marks
that are spaced at 90 degree increments. Use the
rotation index marks as a guide for tightening the
oil filter.
88
Maintenance Section
Fuel System Secondary Filter - Replace
3. Slightly loosen upper secondary fuel filter
element (1) by 90 degrees. As the filter is
loosened, additional fuel may drain. Loosen
the filter by another 90 degrees, and continue
loosening the filter in 90 degree increments until
no fuel drains from the drain valves.
4. Close drain valves (2) and (4).
5. Remove upper secondary fuel filter element (1).
Use care in order to avoid spilling fuel from the
filter element as you remove the element.
Note: The upper secondary fuel filter element and
the lower secondary fuel filter element are different
part numbers.
6. Install a new upper secondary filter element. In
order to prevent contamination of the fuel system,
do not fill the element with fuel before you install
the filter element. When the gasket contacts the
filter base, turn the filter by 270 degrees more.
This will tighten the filter sufficiently.
7. Remove lower secondary fuel filter element (3).
Use caution when you remove the element in
order to avoid spilling the fuel that is in the
element.
8. Install a new lower secondary filter element. In
9. Prime the fuel system. See the Operation and
Maintenance Manual, Fuel System - Prime.
10. Start the engine and check for leaks.
i00794467
Fuel System Secondary Filter -
Replace
(Lower Secondary Filter
Element)
g00366677
Illustration 177
1. Open the access cover on the right side of the
machine.
g00372052
Illustration 178
Note: You must drain the secondary fuel filter
element (1) before the removal or the replacement
of either filter element.
2. Place a suitable container under the valves
(2) and (4). Open the valve (2) in order to
drain the upper secondary fuel filter element
(1). Immediately open the drain valve (4) after
opening the drain valve (2.). This sequence
prevents an air lock in the fuel system.
Note: Every new oil filter has rotation index marks
that are spaced at 90 degree increments. Use the
rotation index marks as a guide for tightening the
oil filter.
89
Maintenance Section
Fuel System Water Separator - Drain
3. Slightly loosen the upper secondary fuel filter
element (1) by 90 degrees. As the filter is
loosened, additional fuel may drain. Loosen
the filter by another 90 degrees, and continue
loosening the filter in 90 degree increments until
no fuel drains from the drain valves.
4. Close the drain valves (2) and (4).
5. If the upper secondary fuel filter element is not
being replaced, tighten the element. When the
gasket contacts the filter base, turn the filter
by 270 degrees more. This will tighten the filter
sufficiently.
6. Remove the lower secondary fuel filter element
(3). Use caution when you remove the element
in order to avoid spilling the fuel that is in the
element.
Note: The upper secondary fuel filter element
and the lower secondary fuel filter element are
different part numbers. Refer to the Operation and
Maintenance Manual, Maintenance Parts List.
7. Install a new lower secondary filter element. In
8. Prime the fuel system. See the Operation and
Maintenance Manual, Fuel System - Prime.
9. Start the engine and check for leaks.
i00795129
Fuel System Water Separator
- Drain
SMCS Code: 1263-543
g00366677
Illustration 179
machine.
g00372736
Illustration 180
2. In order to open the drain valve, turn the valve in
a counterclockwise direction. Allow the water to
drain completely.
3. Drain the water and sediment into a suitable
container.
Note: Dispose of the waste in a proper manner.
i01611532
Fuel Tank Cap Filter and
Strainer - Replace/Clean
SMCS Code: 1273-070-Z2; 1273-070-STR;
1273-510-FI
g00374070
Illustration 181
1. Remove the fuel tank cap.
2. Remove the strainer.
90
Maintenance Section
Fuel Tank Water and Sediment - Drain
3. Wash the strainer in clean, nonflammable solvent.
Dry the strainer with pressure air.
4. Inspect the cap and the strainer. Replace the
cap if the cap is damaged. Replace the strainer
if the strainer is damaged.
5. Install the strainer.
6. Apply a thin film of fuel oil to the gasket of the
fuel tank cap.
7. Install the fuel tank cap.
i00796458
Fuel Tank Water and Sediment
- Drain
SMCS Code: 1273-543-M&S
g00374212
Illustration 182
The drain valve is located on the bottom of the
fuel tank. Drain the water and the sediment into a
suitable container.
Note: Dispose of all fluids according to local
regulations.
i00796495
Fuses - Replace
SMCS Code: 1417-510
Fuse The fuses protect the electrical
system from damage that is caused by
overloaded circuits. Change the fuse if the
element separates. If the element of the new fuse
separates, check the circuit. Repair the problem
before operating the machine.
g00374314
Illustration 183
Starting Aid (1) This is a 10 amp fuse.
Rear Lights (2) This is a 10 amp fuse.
Engine Start Switch (3) This is a 10 amp fuse.
g00374352
Illustration 184
Backup Alarm (4) This is a 10 amp fuse.
Parking Brake Solenoid (5) This is a 10 amp fuse.
Horn (6) This is a 10 amp fuse.
g00374354
Illustration 185
91
Maintenance Section
Hydraulic System Oil - Change
Front Lights and Gauge Lights (7) This is a 10
amp fuse.
Vibration System (8) This is a 10 amp fuse.
Gauges (9) This is a 10 amp fuse.
g00374397
Illustration 186
Windshield Wipers (10) There are two 10 amp
fuses.
Heater (11) This is a 10 amp fuse.
i00797551
Hydraulic System Oil - Change
SMCS Code: 5050-044; 5056-044; 5095-044
NOTICE
Take extreme care to insure the cleanliness of the hy-
draulic oil. Keep the hydraulic oil in order to extend
the component life and assure the maximum perfor-
mance.
g00375232
Illustration 187
1. Remove the hydraulic tank cap and the screen.
2. Wash the hydraulic tank cap and the screen in
clean, nonflammable solvent.
3. Install the screen.
g00375281
Illustration 188
4. Remove the front access cover on the right side
of the machine.
g00375282
Illustration 189
5. Connect a hose to the hydraulic oil tank drain
valve. The drain valve is located on the bottom
of the hydraulic oil tank.
Note: The hydraulic oil tank contains 118 L
(31 US gal)of hydraulic oil. Drain the oil into a
suitable container. Dispose of the used oil in a
proper manner.
6. Close the hydraulic oil tank drain valve. Remove
the hose.
7. Install the front access cover on the right side of
the machine.
8. Refill the hydraulic tank with clean, filtered
hydraulic oil. Refer to the Operation and
Maintenance Manual, Refill Capacities and
Lubricant Viscosities.
9. Remove the hydraulic tank cap. Add the oil
through the filler tube. Clean the cap and install
the cap.
92
Maintenance Section
Hydraulic System Oil Filter - Replace
g00375283
Illustration 190
10. Maintain the oil level at the level mark on the
decal that is near the sight gauge.
11. Install the hydraulic tank cap.
i00799069
Hydraulic System Oil Filter -
Replace
SMCS Code: 5068-510
NOTICE
Take extreme care to insure the cleanliness of the hy-
draulic oil. Keep the hydraulic oil in order to extend
the component life and assure the maximum perfor-
mance.
g00376117
Illustration 191
1. Remove the bolts and remove the panels on
both sides of the machine.
g00376119
Illustration 192
g00376412
Illustration 193
2. Remove the two filter elements. There is one
element for each of the propel pumps. Clean the
filter bases.
3. Install the new filter elements.
g00376495
Illustration 194
4. Start the engine. Allow the hydraulic oil to warm.
Maintain the oil to the level mark on the decal
that is near the sight gauge. If necessary, add oil.
93
Maintenance Section
Hydraulic System Oil Level - Check
i00799435
Hydraulic System Oil Level -
Check
SMCS Code: 5056-535-FLV; 5095-535-FLV
g00375283
Illustration 195
1. Observe the level of the hydraulic oil in the sight
gauge when the oil is warm. Maintain the oil
level to the mark on the decal that is near the
sight gauge.
2. If necessary, add oil.
g00376602
Illustration 196
3. In order to add the oil, remove the filler cap. Add
the oil through the filler tube. Clean the oil filler
cap and install the filler cap.
i00799550
Hydraulic System Oil Sample
- Obtain
SMCS Code: 5050-008; 5095-008
g00376873
Illustration 197
Refer to Operation and Maintenance Manual, SOS
Oil Analysis and to Operation and Maintenance
Manual, Sampling Interval and Location of
Sampling Valve for information that pertains to
obtaining an oil sample from the axle.
i01611546
Hydraulic Tank Strainer - Clean
SMCS Code: 5056-070-STR
g00377033
Illustration 198
1. Remove the hydraulic oil filler cap and pull the
strainer outward.
94
Maintenance Section
Hydraulic Tank Vent - Replace
2. Clean the screen in clean, nonflammable solvent.
Dry the strainer with pressure air.
3. Install the strainer and install the cap.
i01612891
Hydraulic Tank Vent - Replace
SMCS Code: 5056-510-BRE; 5118-510
1. Tilt the cab (if equipped) or tilt the platform
forward. Refer to the Operation and Maintenance
Manual, Cab Tilting or Platform Tilting.
Note: The vent is located on the top of the hydraulic
oil tank.
2. Remove the vent on the hydraulic oil tank.
3. Install the new vent.
4. Lower the cab or the platform. Refer to the
Operation and Maintenance Manual, Cab Tilting
or Platform Tilting.
i00799708
Indicators and Gauges - Test
SMCS Code: 7450-081
g00377039
Illustration 199
g00377044
Illustration 200
Look for gauges that are broken. Look for indicator
lights that are inoperative. Look for switches that
are broken.
Start the engine.
Sound the horn.
Look for inoperative gauges.
Turn on all of the machine lights. Check for proper
operation.
g00377047
Illustration 201
Stop the engine.
Note: When the engine is stopped and the engine
start switch key is turned to theON position, all
four of the indicator lights should illuminate. If the
indicator lights do not illuminate, repair the lights or
replace the lights.
Make all necessary repairs before operating the
machine.
95
Maintenance Section
Neutral Start Switch - Test
i00800145
Neutral Start Switch - Test
SMCS Code: 1424-025; 1424-081; 1424-535
The machine may lurch forward if the neutral start
switch is out of adjustment. Be sure the area is
clear of all personnel and equipment before per-
forming this test.
g00377416
Illustration 202
1. Place the propel lever in the FORWARD position.
g00377417
Illustration 203
2. Hold the engine start switch in the START
position. Slowly move the propel lever toward
the STOP position.
3. If the engine starts before you move the propel
lever to the STOP position. The neutral start
switch requires adjustment. Do not operate the
machine until the repairs have been made.
Consult your Caterpillar dealer for instructions.
i01719384
Oil Filter - Inspect
SMCS Code: 1308-507; 3004-507; 3067-507;
5068-507
Inspect a Used Filter for Debris
g00100013
Illustration 204
The element is shown with debris.
Use a 4C-5084 Filter Cutter or a 175-7546 Oil
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.
96
Maintenance Section
Propel Pump Linkage Rod - Lubricate
i00810362
Propel Pump Linkage Rod -
Lubricate
SMCS Code: 5462-086-KL
g00384472
Illustration 205
1. Remove the access plate.
Note: Wipe all fittings before lubricating the fittings.
g00384492
Illustration 206
2. Lubricate the two fittings on the propel pump
control linkage.
3. Install the access cover.
i00810426
Radiator Core - Clean
SMCS Code: 1353-070-KO
Open the access doors on the left side of the
machine.
g00384500
Illustration 207
The radiator core is located at the rear of the
machine. Open the access door at the rear of the
machine.
g00101939
Illustration 208
Inspect the radiator core for debris. If necessary,
clean the radiator.
Compressed air is preferred, but high pressure
water or steam can be used to remove dust and
general debris from a radiator. Clean the radiator
according to the condition of the radiator.
See Special Publication, SEBD0518, Know Your
Cooling System for more detailed information about
cleaning radiator fins.
Close the access doors. Latch the access doors.
97
Maintenance Section
Rollover Protective Structure (ROPS) - Inspect
i00810518
Rollover Protective Structure
(ROPS) - Inspect
SMCS Code: 7323-040; 7325-040
g00384675
Illustration 209
Inspect the rollover protective structure (ROPS)
for any loose bolts or damaged bolts. Replace
the damaged bolts with original equipment parts
only. Tighten the bolts to a torque of 400 10 Nm
(295 7 lb ft).
Note: Apply oil to all ROPS bolt threads before
installing the bolts. Failure to apply the oil to the
threads can result in an improper bolt torque.
Replace the ROPS mounting support if the ROPS
rattles. Replace the ROPS mounting support if the
ROPS makes noise.
Do not straighten the ROPS or repair the ROPS by
welding reinforcement plates to the ROPS.
Consult your Caterpillar dealer for the repair of the
ROPS.
i01822494
Seat Belt - Inspect
SMCS Code: 7327-040; 7327; 7520
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.
g00932801
Illustration 210
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.
Contact your Caterpillar dealer for the replacement
of the seat belt and 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 each seat belt.
i01866630
Seat Belt - Replace
SMCS Code: 7327-510; 7327
Within three years of the date of installation (2) or
within five years of the date of manufacture (1),
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 each seat belt.
98
Maintenance Section
Steering Cylinder Ends - Lubricate
g00951532
Illustration 211
(1) Date of Manufacture
(2) Date of Installation
Contact your Caterpillar dealer for the replacement
of the seat belt.
i00810901
Steering Cylinder Ends -
Lubricate
SMCS Code: 4303-086-BD
g00384872
Illustration 212
Note: Wipe all of the fittings before lubricating the
fittings.
There is a fitting for each end of the steering
cylinders. There are four fittings.
i00811133
Steering Pivot Clearance -
Adjust
SMCS Code: 4303-025
Refer to the Service Manual for the procedure to
adjust the clearance.
i00811601
Tire Inflation - Check
SMCS Code: 4203-535-PX
g00385434
Illustration 213
If necessary, inflate the tires.
For normal operating conditions, inflate the tires to
the proper pressure:
The proper pressure for the CP-563C is 110 kPa

(16 psi).
The proper pressure for the CS-563C is 83 kPa

(12 psi).
The tire inflation pressure is based on the weight of
a machine that is ready to work and the machine is
without attachments. The pressure is based on the
rated payload, and in average operating conditions.
Pressures for each application may vary. Consult
your Caterpillar dealer for more information about
proper tire inflation pressures.
i00814726
Vibratory Support Oil - Change
g00388211
Illustration 214
99
Maintenance Section
Vibratory Support Oil Level - Check
The vibratory drive gearbox is located on the right
side of the drum.
1. Remove the drain plug. Drain the oil into a
suitable container.
Note: Dispose of the used oil in a proper manner.
2. Clean the drain plug and install the drain plug.
3. Remove the oil level check plug.
g00388234
Illustration 215
4. Remove the oil filler plug.
5. Add the oil through the filler plug opening. Refer
to the Operation and Maintenance Manual,
Lubricant Viscosities and Refill Capacities.
6. Clean the oil level check plug and install the oil
level check plug. Clean the filler plug and install
the filler plug.
i00814904
Vibratory Support Oil Level -
Check
g00388211
Illustration 216
The vibratory drive gearbox is located on the right
side of the drum.
1. Remove the level check plug. Maintain the level
of the oil to the bottom of the level check plug
opening.
g00388234
Illustration 217
2. If the oil level is low, remove the oil filler plug.
3. Add oil in order to maintain the proper level.
4. Clean the level check plug and install the level
check plug. Clean the filler plug and install the
level check plug.
i00814949
Vibratory Support Oil Sample
- Obtain
SMCS Code: 5656-008
g00388211
Illustration 218
Refer to the Operation and Maintenance Manual,
SOS Oil Analysis. Refer to the Operation and
Location of Sampling Valve for information on
obtaining the oil sample from the vibratory support.
100
Maintenance Section
Wheel Nuts - Tighten
i01612983
Wheel Nuts - Tighten
SMCS Code: 4210-527
g00834865
Illustration 219
Tighten the wheel nuts to a torque of 430 60 Nm
(317 44 lb ft).
i00820766
Window Washer Reservoir - Fill
SMCS Code: 7306-544
g00393153
Illustration 220
If the level of the cleaning solution is low, fill the
window washer reservoir. Open the window on the
right side of the cab. Through the window, fill the
reservoir .
i00820730
Window Wiper -
Inspect/Replace
SMCS Code: 7305-040; 7305-510
g00393149
Illustration 221
Inspect the front windshield wiper blade and the
rear windshield wiper blade. If necessary, replace
the windshield wiper blades.
i00892020
Windows - Clean
SMCS Code: 7310-070
Use commercially available window cleaning
solutions in order to clean the windows. Clean the
outside of the cab windows from the ground unless
handholds are available.

Kebu6860-10 M

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Clean the top of the batteries with a clean cloth.

Clean the battery terminals. As needed, coat the

An authorized battery collection facility

Special Publication, SEBU6250, Cooling

Operation and Maintenance Manual,

Complete the information on the label for the

Keep the unused sampling bottles stored in

Obtain coolant samples directly from the coolant

Keep the lids on empty sampling bottles until you

Place the sample in the mailing tube immediately

Never collect samples from expansion bottles.

Never collect samples from the drain for a system.

Use the oil sampling valve (if equipped).

Use a 1U-5718 Vacuum Pump or use an

Cracks in the cylinder head

Other potential engine damage

The proper pressure for the CP-563C is 110 kPa

The proper pressure for the CS-563C is 83 kPa

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