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2010 CaterpillarAll Rights Reserved

MAINTENANCE INTERVALSOperation and MaintenanceManual Excerpt

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KEBU6860-10

June 2003

Operation andMaintenance

ManualCP-563C and CS-563C VibratoryCompactors

4KN1-Up (Machine)4LN1-Up (Machine)

5JN1-Up (Machine)5KN1-Up (Machine)

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57Maintenance Section

Maintenance Interval Schedule

i01924285

Maintenance Interval Schedule

SMCS Code: 1000; 7000

When RequiredBattery - Recycle .................................................. 61Cab Air Filter - Clean/Replace .............................. 62Circuit Breakers - Reset ........................................ 63Cutting Edges (Leveling Blade) - Inspect/

Replace ............................................................... 69Drum Cooling Oil - Change ................................... 70Drum Scrapers - Inspect/Adjust/Replace .............. 70Engine Air Filter Primary Element -

Clean/Replace .................................................... 74Engine Air Filter Secondary Element - Replace ... 76Engine Air Precleaner - Clean .............................. 77Fuel System - Prime ............................................. 86Fuel System Water Separator - Drain ................... 89Fuses - Replace .................................................... 90Oil Filter - Inspect .................................................. 95Wheel Nuts - Tighten .......................................... 100Window Washer Reservoir - Fill .......................... 100Window Wiper - Inspect/Replace ........................ 100

Every 10 Service Hours or Daily

Backup Alarm - Test .............................................. 60Cooling System Coolant Level - Check ................ 67Engine Air Filter Service Indicator - Inspect .......... 76Engine Oil Level - Check ...................................... 78Hydraulic System Oil Level - Check ...................... 93Indicators and Gauges - Test ................................ 94Neutral Start Switch - Test .................................... 95Radiator Core - Clean ........................................... 96Seat Belt - Inspect ................................................ 97Steering Cylinder Ends - Lubricate ....................... 98Windows - Clean ................................................. 100

Every 50 Service Hours or Weekly

Fuel Tank Water and Sediment - Drain ................. 90Tire 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 .. 59Axle Oil Level (Rear) - Check ............................... 60Belts - Inspect/Adjust/Replace .............................. 61Engine Oil Sample - Obtain .................................. 79Engine Oil and Filter - Change ............................. 80Final Drive Planetary (Axle) Oil Level - Check ...... 84Final Drive Planetary (Drum) Oil - Check ............. 85Fuel System Secondary Filter - Replace .............. 88Vibratory Support Oil Level - Check ..................... 99

Initial 500 Hours (for New Systems, RefilledSystems, and Converted Systems)

Cooling System Coolant Sample (Level 2) -Obtain ................................................................. 66

Every 500 Service Hours or 3 MonthsCooling System Coolant Sample (Level 1) -

Obtain ................................................................. 66

Every 500 Service Hours or 6 Months

Axle Oil Sample - Obtain ...................................... 60Final Drive Planetary (Drum) Oil Sample -

Obtain ................................................................. 85Fuel System Primary Filter - Replace ................... 86Fuel System Secondary Filter - Replace .............. 87Hydraulic System Oil Sample - Obtain ................. 93Vibratory Support Oil Sample - Obtain ................. 99

Every 1000 Service Hours or 1 Year

Axle Oil (Rear) - Change ...................................... 59Battery - Clean/Check ........................................... 61Battery or Battery Cable - Inspect/Replace .......... 61Cooling System Pressure Cap - Clean/Replace ... 67Engine Crankcase Breather - Clean ..................... 77Engine Valve Rotators - Inspect ............................ 82Final Drive Planetary (Axle) Oil - Change ............. 83Final Drive Planetary (Axle) Oil Sample - Obtain .. 84Final Drive Planetary (Drum) Oil - Change ........... 84Fuel Tank Cap Filter and Strainer -

Replace/Clean .................................................... 89Hydraulic System Oil - Change ............................. 91

Hydraulic System Oil Filter - Replace ................... 92Hydraulic Tank Strainer - Clean ............................ 93Hydraulic Tank Vent - Replace .............................. 94Propel Pump Linkage Rod - Lubricate .................. 96Rollover Protective Structure (ROPS) - Inspect .... 97Steering Pivot Clearance - Adjust ......................... 98Vibratory 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 ................. 69Engine Governor Oil Supply Screen -

Clean/Inspect/Replace ........................................ 77Engine Valve Lash - Check ................................... 82Fuel Injection Timing - Check ............................... 86

Every Year

Cooling System Coolant Sample (Level 2) -Obtain ................................................................. 66

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Articulating and Oscillating Bearings - Lubricate

i01607989

Articulating and OscillatingBearings - Lubricate

SMCS Code: 7051-086-BD; 7057-086-BD;

7113-086-BD

g00384917Illustration 95

Note:Wipe all of the fittings before lubricating thebearing.

There are two fittings for the articulating bearing.The fittings are located on the rear frame above thepivot housing and below the pivot housing.


Note: Wipe all fittings before lubricating the

bearings.

There are two grease fittings for the oscillatingbearings. There is one fitting for the front bearingand one fitting for the rear bearing. Both greasefittings are located on the left side of the pivothousing.

Note: The fitting for the front bearing is located atthe top of the plate on some machines.

i00780306

Axle Oil (Rear) - Change

SMCS Code: 3260-044


1. Remove the differential drain plug (1). The plugis located at the bottom of the differential case.

Note:Drain the oil into a suitable container. Disposeof the used oil in an appropriate manner.


2. Remove the differential level/fill plug (2). Thedifferential level/fill plug is located on the frontside of the axle.

3. Clean the drain plug (1) and install the drainplug (1). Add the proper oil to the differential.Maintain the level of the oil to the bottom of thehole for the differential level/fill plug. Refer to theOperation and Maintenance Manual, LubricantViscosities and Refill Capacities section formore information.

4. Clean the filler plug. Install the filler plug.

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60Maintenance SectionAxle Oil Level (Rear) - Check

i00801359

Axle Oil Level (Rear) - Check

SMCS Code: 3260-535-FLV


Note:The differential level/fill plug is located on thefront side of the rear axle.

1. Remove the level/fill plug. Maintain the oil levelto the bottom of the level/fill plug opening. Ifnecessary, add oil.

2. Clean the level/fill plug. Install the level/fill plug.

i00803323

Axle Oil Sample - Obtain

SMCS Code: 3260-008


The drain plug (1) is located on the bottom of thedifferential.

Refer to Operation and Maintenance Manual, SOSOil Analysis and to Operation and MaintenanceManual, Sampling Interval and Location ofSampling Valve for information that pertains toobtaining an oil sample from the axle.

i00780980

Backup Alarm - Test

SMCS Code: 7406-081

The backup alarm is located at the rear of themachine.


Turn the engine start switch to the ON position inorder to perform the test.

Apply the parking brake. Move the propel controllever to the REVERSE position.

The backup alarm should start to sound immediately.The backup alarm will continue to sound until thepropel lever is moved to the STOP position or tothe FORWARD position.


In order to adjust the volume level, turn thethree-position selector switch. The switch is locatedon the back of the backup alarm. When the machineis shipped from the factory, the three-positionselector switch is set to the HIGH setting. Thethree-position selector switch should remain at theHIGH setting unless the job site requires a lowervolume level.

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Battery - Clean/Check

i01613063

Battery - Clean/Check

SMCS Code: 1401-535

Note: The batteries that are supplied with themachines are maintenance free batteries. You donot need to check the level of the electrolyte in themaintenance 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. Ifnecessary, 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 followinglocations:

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 OFFposition. Remove the battery disconnect switchkey.

3. At the battery disconnect switch, disconnect thenegative battery cable that is connected to theframe.

Note:Do not allow the disconnected battery cableto contact the disconnect switch.

4. Disconnect the negative battery cable at thebattery.

5. Perform the necessary repairs. Replace thecable or the battery, as needed.

6. Connect the negative battery cable at the battery.

7. Connect the battery cable at the batterydisconnect switch.

8. Install the battery disconnect switch key. Turn thebattery 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 pumpbelt, with a fan drive belt and with accessory drivebelts. Your engine can also be equipped with analternator belt. For maximum engine performanceand maximum utilization of your engine, inspectthe belts for wear and for cracking. Check the belttension. Adjust the belt tension in order to minimizebelt slippage. Belt slippage will decrease the beltlife. Belt slippage will also cause poor performanceof the alternator and of any driven equipment.

If new belts are installed, recheck the beltadjustment after 30 minutes of operation. If two beltsor more are required for an application, replace thebelts in belt sets. If only one belt of a matched setis replaced, the new belt will carry more load. Thisis due to the fact that the older belts are stretched.The additional load on the new belt could cause thenew belt to break.


Open the access cover on the left side of themachine.

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62Maintenance SectionCab Air Filter - Clean/Replace

Alternator Belt and Fan Drive 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).

2. To adjust the alternator belt and the fan drivebelt, loosen bracket bolt (1) and mounting bolt(2) on the alternator bracket.

3. To achieve the correct adjustment, move thealternator inward or move the alternator outward,as required.

4. If necessary, use a pry bar in the square hole inthe alternator bracket.

5. Tighten mounting bolt (2) and bracket bolt (1).

Note:The alternator shaft nut must be tightened toa torque of 50 5 Nm (37 4 lb ft).

6. If new belts are installed, check the beltadjustment again after 30 minutes of engineoperation at the rated speed.

7. Check the position of the fan shroud. Adjust theposition of the fan shroud so that the fan willnot rub against the shroud. Maintain a 9.4 mm(0.38 inch) clearance between the fan and theshroud.

Water Pump Belt

1. To check the belt tension, apply 110 N (25 lb)of force midway between the pulleys. Correctlyadjusted belts will deflect 13 to 19 mm(1/2 to 3/4 inch).


2. To adjust the water pump drive belt, loosenmounting bolt (1) and bracket bolt (3).

3. Move idler pulley (4) in order to achieve thecorrect adjustment.

4. If necessary, use a pry bar in square hole (2) inthe mounting bracket.

5. Tighten mounting bolt (1) and bracket bolt (3).

6. If a new belt is installed, run the engine at ratedspeed for thirty minutes. Check the bolt torque.Readjust the belt, if necessary.

i00782049

Cab Air Filter - Clean/ReplaceSMCS Code: 7342-070; 7342-510


1. Open the filter cover.

2. Clean the filter, or replace the filter.

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Circuit Breakers - Reset

i00782066

Circuit Breakers - Reset

SMCS Code: 1420-529

Circuit Breaker/Reset Push in the buttonin order to reset the circuit breaker. If theelectrical system is functioning properly,

the button will remain depressed. If the buttondoes not remain depressed, check the appropriateelectrical circuit. Repair the electrical circuit, ifnecessary.


This circuit breaker is designed to protect thealternator. For example, if the batteries are installedwith reversed polarity, the circuit breaker wouldprevent 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, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant orsteam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly torelieve pressure only when engine is stopped and

cooling system pressure cap is cool enough totouch with your bare hand.

Do not attempt to tighten hose connections whenthe coolant is hot, the hose can come off causingburns.

Cooling System Coolant Additive contains alkali.Avoid contact with skin and eyes.

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

Refer to Special Publication, NENG2500, CaterpillarTools and Shop Products Guide for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

NOTICE

Do not change the coolant until you read and under-stand the material in the Cooling System Specifica-tions section.

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64Maintenance SectionCooling System Coolant (ELC) - Change

NOTICEMixing Extended Life Coolant (ELC) with other prod-ucts reduces the effectiveness of the coolant andshortens 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 withCaterpillar ELC. Failure to follow these recommenda-tions could result in the damage to cooling systemscomponents.

If ELC cooling system contamination occurs, refer toOperation and Maintenance, Extended Life Coolant(ELC) under the topic ELC Cooling System Contam-ination.

Drain the coolant whenever the coolant is dirty orwhenever foaming is observed.


1. Slowly loosen the radiator cap in order to relievethe pressure. Slowly remove the radiator cap.


2. Open the radiator guard on the rear of themachine. The drain valve is located on thebottom corner of the radiator. Open the drainvalve. Allow the coolant to drain into a suitablecontainer.

3. Close the drain valve. Fill the system with asolution which consists of clean water and ofcooling system cleaner. The concentration of thecooling system cleaner in the solution should bebetween 6 percent and 10 percent.

4. Start the engine. Run the engine for 90 minutes.Stop the engine. Drain the cleaning solution intoa suitable container.

5. While the engine is stopped, flush the systemwith water. Flush the system until the drainingwater is transparent.

6. Close the drain valve.

7. Add the coolant solution. See the followingtopics:

Special Publication, SEBU6250, Cooling

System Specifications

Operation and Maintenance Manual,Capacities (Refill)

Note:If you are using Caterpillar antifreeze, do notadd the supplemental coolant additive at this timeand/or change the element at this time.

8. Start the engine. Run the engine without theradiator cap until the thermostat opens and thecoolant 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 isdamaged. Install the radiator cap.

11. Stop the engine.

12. Close and lock the access covers.

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Cooling System Coolant Extender (ELC) - Add

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Cooling System CoolantExtender (ELC) - Add

SMCS Code:1352-544-NL

At operating temperature, the engine coolant ishot and under pressure.

Steam can cause personal injury.

Check the coolant level only after the engine hasbeen stopped and the fill cap is cool enough totouch with your bare hand.

Remove the fill cap slowly to relieve pressure.

Cooling system conditioner contains alkali. Avoidcontact with the skin and eyes to prevent personalinjury.

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

Refer to Special Publication, NENG2500, CaterpillarTools and Shop Products Guide for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

When a Caterpillar Extended Life Coolant (ELC) isused, an Extender must be added to the coolingsystem. See the Cooling System Specificationsin the Operation and Maintenance Manual for allcooling system requirements.

Use a 8T-5296 Coolant Test Kit to check theconcentration of the coolant.

For additional information about the addition ofExtender, see the Operation and MaintenanceManual, Cooling System Specifications or consultyour Caterpillar dealer.

NOTICEMixing ELC with other products that do not meetCaterpillar EC-1 specifications reduces the effective-ness of the coolant and shortens coolant service life.

Use only Caterpillar products or commercial productsthat have passed the Caterpillar EC-1 specificationfor pre-mixed or concentrate coolants. Use onlyCaterpillar Extender with Caterpillar ELC.

Failure to follow these recommendations can result inshortened cooling system component life.


1. Slowly loosen the cooling system pressure capin order to relieve system pressure. Remove thecooling system pressure cap.

2. If necessary, drain enough coolant from theradiator in order to allow the addition of theExtender.

3. Add the recommended amount of extender tothe coolant system. Refer to Operation andMaintenance Manual, Extended Life Coolant(ELC) for the proper amount of the ELC Extenderthat needs to be added to the cooling system.

4. Maintain the coolant level 1 cm (0.5 inch) fromthe bottom of the radiator filler pipe.

5. Inspect the gasket on the pressure cap, andreplace the filler cap if the gasket is damaged.

6. Install the cooling system pressure cap.

For additional information on the addition ofextender, see Special Publication, SEBU6250,Coolant Recommendations or consult yourCaterpillar dealer.

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66Maintenance SectionCooling System Coolant Sample (Level 1) - Obtain

i01933615

Cooling System CoolantSample (Level 1) - Obtain

SMCS Code: 1350-008; 1395-008; 7542

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.

Note:Level 1 results may indicate a need forLevel 2 Analysis.


Obtain the sample of the coolant as close aspossible to the recommended sampling interval. Inorder to receive the full effect of SOS analysis, youmust establish a consistent trend of data. In orderto establish a pertinent history of data, performconsistent samplings that are evenly spaced.Supplies for collecting samples can be obtainedfrom your Caterpillar dealer.

Use the following guidelines for proper samplingof the coolant:

Complete the information on the label for thesampling bottle before you begin to take thesamples.

Keep the unused sampling bottles stored inplastic bags.

Obtain coolant samples directly from the coolantsample port. You should not obtain the samplesfrom any other location.

Keep the lids on empty sampling bottles until youare ready to collect the sample.

Place the sample in the mailing tube immediatelyafter obtaining the sample in order to avoidcontamination.

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, CaterpillarMachine Fluids Recommendations or consult yourCaterpillar dealer.

i01933616

Cooling System CoolantSample (Level 2) - Obtain

SMCS Code: 1350-008; 1395-008; 7542

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.


Obtain the sample of the coolant as close aspossible to the recommended sampling interval.Supplies for collecting samples can be obtainedfrom your Caterpillar dealer.

Refer to Operation and Maintenance Manual,Cooling System Coolant Sample (Level 1) - Obtainfor the guidelines for proper sampling of the coolant.

Submit the sample for Level 2 analysis.

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Cooling System Coolant Level - Check

For additional information about coolant analysis,see Special Publication, SEBU6250, CaterpillarMachine Fluids Recommendations or consult yourCaterpillar dealer.

i01933901

Cooling System Coolant Level- Check

SMCS Code: 1350-535-FLV; 1395-535-FLV







1. Slowly loosen the pressure cap in order to

release any pressure in the system. Slowlyremove the pressure cap.

2. Maintain the coolant level 1 cm (0.5 inch) fromthe bottom of the filler pipe. If it is necessary toadd coolant daily, check the cooling system forleaks. 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 aredamaged.

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, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant orsteam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly torelieve pressure only when engine is stopped and

cooling system pressure cap is cool enough totouch with your bare hand.

Do not attempt to tighten hose connections whenthe coolant is hot, the hose can come off causingburns.

Cooling System Coolant Additive contains alkali.Avoid contact with skin and eyes.


1. The radiator cap is on the top right rear of themachine.

2. Remove the radiator cap slowly in order torelieve pressure.

3. Inspect the radiator cap for foreign material, fordeposits, and for damage. Clean the radiatorcap with a clean cloth. If the radiator cap isdamaged, replace the radiator cap.

4. Install the radiator cap.

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68Maintenance SectionCooling System Water Temperature Regulator - Replace

i00803482

Cooling System WaterTemperature Regulator -Replace

SMCS Code: 1355-510; 1393-010






Replace the water temperature regulator on aregular basis in order to reduce the chance ofunscheduled downtime and of problems with thecooling system.

The water temperature regulator should be replacedafter the cooling system has been cleaned. Replace

the water temperature regulator while the coolingsystem is completely drained. Replace the watertemperature regulator while the cooling systemcoolant is drained to a level below the watertemperature regulator housing.

NOTICEFailure to replace the engines water temperature reg-ulator on a regularly scheduled basis could cause se-vere engine damage.


Note:If you are only replacing the water temperatureregulator, drain the cooling system coolant to alevel that is below the water temperature regulatorhousing.

1. Remove the radiator cap in order to relieve the

pressure.


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 temperatureregulator housing (3) and remove the watertemperature regulator housing (3).

4. Remove the gasket and remove the watertemperature regulator from the water temperature

regulator housing. Make a note of the orientationof the old regulator.

NOTICEFormer water temperature regulators may be used, ifthey meet test specifications and are not damaged orhave excessive buildup or deposits.

NOTICESince Caterpillar engines incorporate a shunt designcooling system, it is mandatory to always operate theengine with a water temperature regulator.

Depending on load, failure to operate with a water tem-perature regulator could result in either an overheatingor an overcooling condition.

NOTICEIf the water temperature regulator is installed incor-rectly, it will cause the engine to overheat.

5. Install a new water temperature regulator. Orientthe regulator in the same manner as the oldregulator. Install a new gasket. Install the watertemperature regulator housing.

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Crankshaft Vibration Damper - Inspect

6. Install the water temperature regulator housingand the hose. Tighten the hose clamp.

7. Add the cooling system coolant. Maintain thecoolant level within 1 cm (0.5 inch) of the bottomof the filler tube.

8. Inspect pressure cap and the gasket for damage.Replace the pressure cap if the pressure cap orthe gasket are damaged.

9. Install the pressure cap.

i00803692

Crankshaft Vibration Damper- Inspect

SMCS Code: 1205-040



Damage to the crankshaft vibration damper orfailure of the crankshaft vibration damper canincrease torsional vibrations. This can result indamage to the crankshaft and to other enginecomponents. A deteriorating damper can causeexcessive gear train noise at variable points in thespeed range.

The damper is mounted to the crankshaft on thefront of the engine.

Visually inspect the crankshaft vibration damper fordamage.

Check the bolts for proper tightness. Refer tothe Operation and Maintenance Manual, TorqueSpecifications.

i01608507

Cutting Edges (Leveling Blade)- Inspect/Replace

SMCS Code: 6801-040; 6801-510

Personal injury or death can result if the levellingblade is not blocked up. Block the levelling bladebefore changing the cutting edge.


Replace the cutting edge if the cutting edge isdamaged. Replace the cutting edge if the cuttingedge is excessively worn.

1. Raise the leveling blade. Block the leveling bladesecurely.

In order to change the cutting edge, block theblade at a level that is just high enough tochange 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 notworn, use the opposite edge. If the oppositeedge is worn, replace the cutting edge.

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Eccentric Weight Housing Oil - Change

Padded Drum Scraper Assembly (IfEquipped)

Adjust

There are two scrapers. One scraper is in front ofthe drum. The second scraper is at the rear of thedrum.

1. Inspect the scraper. Clean the dirt and the debrisfrom the scraper.


2. Loosen the four nuts on each end of the scraperassembly.


3. Slide the scraper toward the drum. Adjust thetips so the tips are 19 mm (0.75 inch) from thesurface of the drum.

4. Tighten the nuts.

i01208037

Eccentric Weight Housing Oil- Change

SMCS Code:6606-044-OC

Change the Oil

1. Take an oil sample from each eccentric weighthousing. There is one eccentric weight housingon each side of the drum. No flushing isnecessary, if the oil sample rating is equal orlower than ISO 23/21. The flushing procedureshould be performed if an oil sample rating ishigher than ISO 23/21.


2. Rotate the drum until the welded item is at thetop of the drum. The drain plug is at the bottomof the housing.

3. Place a suitable container under the drain plug.Remove the drain plug. Drain the housingcompletely. Repeat this step for both housings.

4. Clean the plug. Install the plug.

5. Rotate the drum until the welded item is at thebottom of the drum.


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72Maintenance SectionEccentric Weight Housing Oil - Change

6. Remove the filler plug.


7. Remove the level check plug. Fill the housingwith oil. Refer to the Operation and Maintenance

Manual, Lubrication Viscosities and Operationand Maintenance Manual, Refill Capacities.Maintain the level of the oil to the bottom of thelevel check opening.

8. Clean the plugs. Install the plugs.

9. Repeat this procedure for the other eccentricweight housing.

Flush the Housing


1. There are two eccentric weight housings. Thehousings are on each side of the drum. Performthe following procedure on each housing.

2. Drain the oil from the eccentric weight housings.


3. Pump 151 L (40 US gal) of a suitable hydraulicoil into a 208 L (55 US gal) drum.


(1) 8C-6875Connector(2) 8B-5774Reducer Bushing(3) 9U-6989Head(4) 9U-6983Filter Element(5) 6V-3965Nipple Assembly(6) 8T-4834Swivel Orifice Tee(7) 127-8781 Filter Cart(8) 2.4 m (8 ft) of 25 mm (1 inch) diameter hose.

(9) 3B-6498Elbow(10) 3L-7024Street Elbow(11) 127-0593Connector(12) 3B-7728Elbow(13) 3B-7265Pipe 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 orderto flush the oil in the 208 L (55 US gal) drum.Filter the oil for 30 minutes. The particle count ofthe clean oil must be a maximum of ISO 18/13.

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Eccentric Weight Housing Oil - Change


5. Raise the machine. The drum and tires mustnot be in contact with the ground or the floor.Support the machine on stands.


6. Start the engine. Release the parking brake androtate the drum until the fill/drain plug is at thetop of the housing. Remove the plug. Install thevalve and fitting assembly that is appropriate foryour machine.


7. Assemble the 126-7187 Adapter (20) intothe male end of the 5R-3796 Quick CouplingAssembly (19). Install the adapter into the holefor the oil fill/drain plug. Assemble the 8T-0198Seal Connector (18) onto the female end of thequick coupler. Attach the female end of the quick

coupler to the transfer cart suction hose in orderto drain the flushing oil from the housing.


8. Rotate the drum until the fill/drain plug is at thebottom. Put a mark on the surface of the drum atthe top of the drum. The mark will help identifythe position of the fill/drain plug.


9. Remove the level check plug. Connect the quickcoupler (19). Fill the housing with 22 L (6 US gal)

gallons of clean oil. Install the plug.

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74Maintenance SectionEngine Air Filter Primary Element - Clean/Replace


10. Run the first flush cycle.

a. Start the engine. Release the brake.

b. Set the travel speed control to low speed. Inorder to rotate the drum, move the propelcontrol.

c. Set the vibratory amplitude control to the lowposition.

d. Turn on the vibratory system. Run the vibratorysystem for 5 seconds. Turn off the vibratorysystem. Repeat the cycle for three minutes.

Note:For each cycle, do not run the vibratorysystem more than 5 seconds.

e. Stop the drum. Position the drum in order todrain the housings.

11. Install the transfer cart. Pump the oil out of thehousings. Cycle the oil through the filter for 30minutes. Cycle the oil until the oil is cleaned toa rating of ISO 18/13 or better.

12. Install the transfer cart to the housings. Pumpthe 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. Nofurther flushing is necessary, if the oil sample

rating is equal or lower than ISO 19/16. Anotherflushing is necessary, if the oil sample rating ishigher than ISO 19/16.

13. When the flushing is complete, rotate the drumto the position in order to drain the housings.Remove the valve and fitting assembly. Drain asmuch of the oil as possible.

14. Rotate the drum until the fill/drain plug is at thetop. Remove the level check plug. Fill the drumto the correct level. Refer to the Operation andMaintenance Manual, Lubrication Specificationsand Refill Capacities.

Note:The new oil must have a oil sample rating thatis equal or lower than ISO 18/15.

i01822655

Engine Air Filter PrimaryElement - Clean/Replace

SMCS Code:1054-070-PY; 1054-510-PY

NOTICEService the air cleaner only with the engine stopped.Engine damage could result.

Service the air cleaner filter element when theyellow piston on the engine air filter serviceindicator enters the red zone or the indicatorreads 63.5 cm (25 inch) of water. Refer to

Operation and Maintenance Manual, Engine AirFilter Service Indicator - Inspect.

1. Open the access door on the left side of themachine.


2. Squeeze the outlet tube slightly in order to purgethe dirt from the outlet tube.


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Engine Air Filter Primary Element - Clean/Replace

3. Loosen the four cover latches and remove theair cleaner cover.


4. Remove the primary filter element from the air

cleaner housing.

5. Clean the air cleaner cover and the inside of theair cleaner housing.

6. Inspect the O-ring seal on the air cleaner cover.Replace the O-ring seal if the O-ring seal is wornor damaged.

NOTICEDo not clean the filter elements by bumping or tappingthem. Do not use filter elements with damaged pleats,gaskets or seals. Engine damage can result.

Make sure the cleaned filter elements are completelydry before installing into the filter housing. Water re-maining in the elements can cause false indications ofcontamination in Scheduled Oil Sampling test results.

7. Clean the primary filter. Inspect the primary filter.

Primary filter elements can be cleaned with lowpressure air. Caterpillar does not recommendcleaning the air filter.

Refer to Operation and Maintenance, GeneralHazard Information before you use pressure air

in order to clean the primary filter element.


8. Direct air along the pleats inside the primary filterelement and outside the primary filter element.Do not touch pleats with the air nozzle.

9. Inspect the primary filter element after theelement is clean. Do not use a primary filterelement with damaged pleats, damaged gasketsor damaged seals.

10. Encase the clean primary filter element andstore the clean primary filter element in a clean,dry place.

11. Install the clean primary filter.

12. Install the air cleaner cover and close thelatches securely.


Note: Install the air cleaner cover properly. Thearrows must point upward.

13. Change the filter if the exhaust smoke is stillblack.

Note:Replace the primary filter if the primary filterhas been in service for one year.

14. Close the access door.

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76Maintenance SectionEngine Air Filter Secondary Element - Replace

i01822684

Engine Air Filter SecondaryElement - Replace

SMCS Code:1054-510-SE

NOTICEAlways 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 replacedif 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, EngineAir Filter Primary Element - Clean/Replace.Remove the air cleaner cover from the air cleanerhousing. Remove the primary filter element fromthe air cleaner housing.


3. Remove the secondary filter element.

4. Cover the air inlet opening. Clean the inside ofthe 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 latchessecurely.


i00788847

Engine Air Filter ServiceIndicator - Inspect

SMCS Code: 7452-040


1. Open the engine compartment access door.

2. Start the engine.

3. Run the engine at high idle.


4. If the yellow piston in the engine air filter serviceindicator enters the red zone, service the aircleaner.

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.

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Engine Air Precleaner - Clean

i00788900

Engine Air Precleaner - Clean

SMCS Code: 1055-070


1. Check the precleaner for accumulation of trashand dirt.

2. Empty the bowl whenever the dirt is present inthe 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 thewing nut. Do not use a tool to tighten the wingnut.

i00788960

Engine Crankcase Breather -Clean

SMCS Code: 1317-070


1. Open the access door on the right side of themachine.


2. Loosen the hose clamp (2). Remove the hose

(3) from the breather.

3. Remove bolt (4). Remove the breather (4) andthe O-ring seal.

4. Wash the breather (4) in clean nonflammablesolvent. 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 SupplyScreen - Clean/Inspect/Replace

SMCS Code: 1264-510-Z3; 1264-571-Z3;1278-510-Z3; 1278-571-Z3


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78Maintenance SectionEngine Mounts - Inspect



2. Remove the oil supply tube (1) from the cylinder

head.

3. Remove the fitting (3) and the seal (2) from thegovernor housing.

4. Use a 6 mm hexagon wrench in order to removethe screen (4).

5. Wash the screen (4) in solvent in order to removeany debris.

6. Inspect the screen (4) for damage. Replacedamaged parts.

7. Install the screen (4). Allow clearance for thefitting (3).

8. Install the seal (2). Install the fitting (3). Installthe oil supply tube (1).


i00808262

Engine Mounts - Inspect

SMCS Code: 1152-040


Engine vibration can be caused by impropermounting of the engine. Engine vibration can becaused by loose engine mounts or deterioratedengine 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 enginemount to 450 Nm (331 lb ft). Torque the rear mountsto 220 Nm (162 lb ft).

i00789760

Engine Oil Level - Check


NOTICEDo 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. DONOT check the oil level when the engine is running.

Park the machine on a level surface.

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Engine Oil Sample - Obtain




2. Remove the dipstick (1). Wipe the dipstick with aclean cloth. Insert the dipstick (1). Remove thedipstick and note the oil level. Insert the dipstick.

Note: Refer to the Operation and MaintenanceManual, Lubricant Viscosities and Refill Capacitiesfor the correct amount of oil that is used when theoil is changed. The correct amount of oil determinesthe correct level of the oil in the FULL range on thedipstick.

NOTICE

Do not overfill the crankcase. The oil level must notreach the top of the FULL range mark or above theFULLrange mark.


3. Maintain the oil level on the dipstick between theFULL RANGE mark and the ADD OIL mark .Add oil if the oil level is too low.

Note:Operating your engine with the oil level abovethe FULL mark in the FULL RANGE could causethe crankshaft to dip into the oil. This could resultin excessively high operating temperatures. Thehigh operating temperatures could result in reducedlubricating characteristics of the oil. This couldcause damage to the bearings and loss of enginepower.

4. Remove the oil filler plug (2).

5. Add the oil.

6. Clean the oil filler plug (2). Install the oil fillerplug (2).


i00790311

Engine Oil Sample - Obtain

SMCS Code: 1348-008

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.

Obtain the Sample and the Analysis

In addition to a good preventive maintenanceprogram, Caterpillar recommends using SOS oilanalysis at regular scheduled intervals in orderto monitor the condition of the engine and themaintenance requirements of the engine.

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80Maintenance SectionEngine Oil and Filter - Change

Each oil sample should be taken when the oil iswarm and when the oil is well mixed. The sampleshould be taken at this time in order to ensurethat the sample is representative of the oil in thecrankcase.

Obtain the SOS Sample

Use one of the following methods in order to obtainan SOS sample:

Use the oil sampling valve (if equipped).

Use a 1U-5718 Vacuum Pump or use anequivalent pump that is inserted into the sump.

Caterpillar recommends using the sampling valve(if equipped) in order to obtain oil samples. Thequality and the consistency of the samples is betterwhen the sampling valve is used. If the engine is

not equipped with a sampling valve, the use of a1U-5718 Vacuum Pump is preferred.

To avoid contamination of the oil samples, the toolsand the supplies that are used for obtaining oilsamples must be clean.

Refer to Special Publication, PEHP6001 for moreinformation on obtaining a good oil sample. Consultyour Caterpillar dealer for complete information andassistance in establishing an SOS program foryour engine.


1. Open the engine access door on the right sideof the machine.


2. The oil sampling valve is on the right side of theengine. The oil sampling valve is located abovethe governor.

3. Open the sampling valve. Obtain an oil samplein a suitable container and close the samplingvalve.

4. Seal the container and label the container. Sendthe sample to your Caterpillar dealer for analysis.

5. Close the engine access door and secure thedoor.

i00790346

Engine Oil and Filter - Change

SMCS Code: 1318-510

Run the engine in order to warm up the oil. Stopthe engine before draining the oil. When the oil iswarm the waste particles are suspended in the oil.The waste particles will be removed when the oilis drained.

As the oil cools, the waste particles settle to thebottom of the oil pan. The waste particles will notbe removed if the oil is too cool.

The waste particles can recirculate through the

engine lubrication system if the recommendedprocedure is not followed.

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82Maintenance SectionEngine Valve Lash - Check

NOTICEDo not overfill to reach above or to the top of the FULLRANGE on the dipstick.

Operating your engine when the oil level is above

the FULL mark in the FULL RANGE could cause thecrankshaft to dip into the oil. This could lead to ex-cessively high oil temperatures, which can reduce thelubricating characteristics of the oil, leading to bearingdamage, and could result in the loss of engine power.


11. Before starting the engine, check the oil levelon the dipstick. The oil level must be within theFULL 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 oilto drain back into the crankcase. Check theoil level. Maintain the oil level within the FULLRANGE on the dipstick.

14. Close the access doors and secure the accessdoors.

i00687328

Engine Valve Lash - Check

SMCS Code: 1105-535

This maintenance is recommended by Caterpillaras part of a lubrication and preventive maintenanceschedule in order to help provide maximum enginelife.

NOTICEOnly qualified service personnel should perform thismaintenance. Refer to the Service Manual or yourCaterpillar dealer for the complete valve lash adjust-ment procedure.

Operation of Caterpillar engines with improper valveadjustments can reduce engine efficiency. This re-duced efficiency could result in excessive fuel usageand/or shortened engine component life.

Ensure that the engine can not be started whilethis maintenance is being performed. To help pre-vent possible injury, do not use the starting motorto turn the flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring/adjusting valve lash clearance.

Ensure that the engine is stopped before measuringthe valve lash. To obtain an accurate measurement,allow the valves to cool before this maintenanceis performed.

Refer to the Service Manual for more information.

i01597115

Engine Valve Rotators - InspectSMCS Code: 1109-040

When inspecting the valve rotators, protectiveglasses or face shield and protective clothingmust be worn, to help prevent being burned byhot oil or spray.

Engine valve rotators rotate the valves when theengine runs. This helps to prevent deposits from

building up on the valves and the valve seats.

Perform the following steps after the engine valvelash is set, but before the valve covers are installed:

1. Start the engine according to Operationand Maintenance Manual, Engine Starting(Operation Section) for the procedure.

2. Operate the engine at low idle.

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Engine Water Pump - Inspect

3. Observe the top surface of each valve rotator.The valve rotators should turn slightly when thevalves close.

NOTICEA valve rotator which does not operate properly will

accelerate valve face wear and valve seat wear andshorten valve life. If a damaged rotator is not replaced,valve face guttering could result and cause pieces ofthe valve to fall into the cylinder. This can cause pistonand cylinder head damage.

If a valve fails to rotate, consult your Caterpillardealer.

i00808554

Engine Water Pump - Inspect

SMCS Code: 1361-040

A water pump that has failed might cause severeengine overheating. Severe engine overheatingcould result in the following problems:

Cracks in the cylinder head

Piston seizure

Other potential engine damage


Visually inspect the water pump for leaks. If leaksare found, all the seals must be replaced.

Note:See the Service Manual for your machine formore information about this topic.

i01608624

Final Drive Planetary (Axle) Oil- Change



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 thebottom 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 levelcheck/fill plug.

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84Maintenance SectionFinal Drive Planetary (Axle) Oil Level - Check

i01608878

Final Drive Planetary (Axle) OilLevel - Check



1. In order to check the level of the oil in theplanetary, remove level check/fill plug (1).Maintain the level of the oil to the bottom of thelevel check/fill plug opening.

2. If necessary, add oil.

3. Clean the level check/fill plug and install the plug.

i01608923

Final Drive Planetary (Axle) OilSample - Obtain

SMCS Code: 4050-008


Obtain the oil sample when you change the oil.

Refer to the Operation and Maintenance Manual,SOS Oil Analysis. Refer to the Operation andMaintenance Manual, Sampling Interval andLocation of Sampling Valve for information onobtaining the oil sample from the planetary.

i01608930

Final Drive Planetary (Drum)Oil - Change

SMCS Code: 4050-044-OC; 5655-044-OC


1. Rotate the drum until fill/drain plug (1) is locatedat the bottom.

2. Remove fill/drain plug (1). Drain the oil into

a suitable container. Dispose of the oil in anacceptable manner.

3. After the oil is drained, install fill/drain plug (1).

4. Rotate the drum until fill/drain plug (1) is locatedat the top of the planetary and plug (2) is locatedat 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 ofthe level check plug opening.(2).

7. Clean plugs (1) and (2). Install plugs (1) and (2).

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Final Drive Planetary (Drum) Oil - Check

i01609277

Final Drive Planetary (Drum)Oil - Check

SMCS Code: 4050-535-FLV; 5655-535-FLV


The final drive planetary for the drum is located onthe left side of the drum.


1. Rotate the drum until plug (1) is located at the90 degree position.

2. Remove the level check plug. Check the level ofthe oil in the planetary. Maintain the level of theoil at the bottom of the level check plug opening.


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

Final Drive Planetary (Drum)Oil Sample - Obtain

SMCS Code: 4050-008; 5655-008



Refer to Operation and Maintenance Manual,SOS Oil Analysis and refer to Operation andMaintenance Manual, Sampling Interval andLocation of Sampling Valve for information thatpertains to obtaining an oil sample from the axle.

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86Maintenance SectionFuel Injection Timing - Check

i00675887

Fuel Injection Timing - Check

SMCS Code: 1290-531-FT

A qualified mechanic should adjust the fuel injectortiming because special tools and training arerequired.

Note: The correct fuel timing specification isfound on the Engine Information Plate. Fueltiming specifications may vary for different engineapplications and/or for different power ratings.

i00793376

Fuel System - Prime

SMCS Code: 1250-548




2. Open the valve (2). Push the plunger (1) until thefuel 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




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). Removebowl (5) and collar (5).

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Fuel System Secondary Filter - Replace


5. Loosen collar (2). Remove element (3). Discardthe element in a proper manner.

6. Clean the parts. Inspect the parts for damage.

Replace the damaged parts or replace the wornparts.

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 forleaks.

10. Close the access door and secure the accessdoor.

i01611470

Fuel System Secondary Filter -Replace

SMCS Code:1261-510-SE


1. Open the access cover on the right side of themachine.


Note:You must drain secondary fuel filter element(1) before the removal or the replacement of eitherfilter element.

2. Place a suitable container under valves (2)and (4). Open valve (2) in order to drain upper

secondary fuel filter element (1). Immediatelyopen drain valve (4) after opening drain valve(2). This sequence prevents an air lock in thefuel system.

Note:Every new oil filter has rotation index marksthat are spaced at 90 degree increments. Use therotation index marks as a guide for tightening theoil filter.

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88Maintenance SectionFuel System Secondary Filter - Replace

3. Slightly loosen upper secondary fuel filterelement (1) by 90 degrees. As the filter isloosened, additional fuel may drain. Loosenthe filter by another 90 degrees, and continueloosening the filter in 90 degree increments untilno 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 thefilter element as you remove the element.

Note:The upper secondary fuel filter element andthe lower secondary fuel filter element are differentpart numbers.

6. Install a new upper secondary filter element. Inorder to prevent contamination of the fuel system,do not fill the element with fuel before you install

the filter element. When the gasket contacts thefilter 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 inorder to avoid spilling the fuel that is in theelement.

8. Install a new lower secondary filter element. Inorder to prevent contamination of the fuel system,do not fill the element with fuel before you installthe filter element. When the gasket contacts thefilter base, turn the filter by 270 degrees more.

This will tighten the filter sufficiently.

9. Prime the fuel system. See the Operation andMaintenance Manual, Fuel System - Prime.

10. Start the engine and check for leaks.


i00794467

Fuel System Secondary Filter -Replace(Lower Secondary Filter

Element)SMCS Code:1261-510-SE


1. Open the access cover on the right side of themachine.


Note: You must drain the secondary fuel filterelement (1) before the removal or the replacementof either filter element.

2. Place a suitable container under the valves(2) and (4). Open the valve (2) in order todrain the upper secondary fuel filter element(1). Immediately open the drain valve (4) afteropening the drain valve (2.). This sequenceprevents an air lock in the fuel system.

Note:Every new oil filter has rotation index marksthat are spaced at 90 degree increments. Use therotation index marks as a guide for tightening theoil filter.

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Fuel System Water Separator - Drain

3. Slightly loosen the upper secondary fuel filterelement (1) by 90 degrees. As the filter isloosened, additional fuel may drain. Loosenthe filter by another 90 degrees, and continueloosening the filter in 90 degree increments untilno fuel drains from the drain valves.

4. Close the drain valves (2) and (4).

5. If the upper secondary fuel filter element is notbeing replaced, tighten the element. When thegasket contacts the filter base, turn the filterby 270 degrees more. This will tighten the filtersufficiently.

6. Remove the lower secondary fuel filter element(3). Use caution when you remove the elementin order to avoid spilling the fuel that is in theelement.

Note: The upper secondary fuel filter elementand the lower secondary fuel filter element aredifferent part numbers. Refer to the Operation andMaintenance Manual, Maintenance Parts List.

7. Install a new lower secondary filter element. Inorder to prevent contamination of the fuel system,do not fill the element with fuel before you installthe filter element. When the gasket contacts thefilter base, turn the filter by 270 degrees more.This will tighten the filter sufficiently.

8. Prime the fuel system. See the Operation andMaintenance Manual, Fuel System - Prime.

9. Start the engine and check for leaks.


i00795129

Fuel System Water Separator- Drain

SMCS Code: 1263-543




2. In order to open the drain valve, turn the valve in

a counterclockwise direction. Allow the water todrain completely.

3. Drain the water and sediment into a suitablecontainer.

Note:Dispose of the waste in a proper manner.

4. Close the drain valve.


i01611532

Fuel Tank Cap Filter andStrainer - Replace/Clean

SMCS Code: 1273-070-Z2; 1273-070-STR;1273-510-FI


1. Remove the fuel tank cap.

2. Remove the strainer.

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90Maintenance SectionFuel 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 thecap if the cap is damaged. Replace the strainerif the strainer is damaged.

5. Install the strainer.

6. Apply a thin film of fuel oil to the gasket of thefuel tank cap.

7. Install the fuel tank cap.

i00796458

Fuel Tank Water and Sediment- Drain

SMCS Code:1273-543-M&S


The drain valve is located on the bottom of thefuel tank. Drain the water and the sediment into asuitable container.

Note: Dispose of all fluids according to localregulations.

i00796495

Fuses - Replace

SMCS Code: 1417-510

Fuse The fuses protect the electricalsystem from damage that is caused byoverloaded circuits. Change the fuse if the

element separates. If the element of the new fuseseparates, check the circuit. Repair the problembefore operating the machine.


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.


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.


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Hydraulic System Oil - Change

Front Lights and Gauge Lights (7) This is a 10amp fuse.

Vibration System (8) This is a 10 amp fuse.

Gauges (9) This is a 10 amp fuse.


Windshield Wipers (10) There are two 10 ampfuses.

Heater (11) This is a 10 amp fuse.

i00797551

Hydraulic System Oil - Change

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

NOTICETake extreme care to insure the cleanliness of the hy-draulic oil. Keep the hydraulic oil in order to extendthe component life and assure the maximum perfor-mance.


1. Remove the hydraulic tank cap and the screen.

2. Wash the hydraulic tank cap and the screen inclean, nonflammable solvent.

3. Install the screen.


4. Remove the front access cover on the right sideof the machine.


5. Connect a hose to the hydraulic oil tank drainvalve. The drain valve is located on the bottomof the hydraulic oil tank.

Note: The hydraulic oil tank contains 118 L(31 US gal)of hydraulic oil. Drain the oil into asuitable container. Dispose of the used oil in aproper manner.

6. Close the hydraulic oil tank drain valve. Removethe hose.

7. Install the front access cover on the right side ofthe machine.

8. Refill the hydraulic tank with clean, filteredhydraulic oil. Refer to the Operation andMaintenance Manual, Refill Capacities andLubricant Viscosities.

9. Remove the hydraulic tank cap. Add the oilthrough the filler tube. Clean the cap and installthe cap.

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92Maintenance SectionHydraulic System Oil Filter - Replace


10. Maintain the oil level at the level mark on thedecal that is near the sight gauge.

11. Install the hydraulic tank cap.

i00799069

Hydraulic System Oil Filter -Replace

SMCS Code: 5068-510

NOTICETake extreme care to insure the cleanliness of the hy-draulic oil. Keep the hydraulic oil in order to extendthe component life and assure the maximum perfor-

mance.


1. Remove the bolts and remove the panels onboth sides of the machine.



2. Remove the two filter elements. There is oneelement for each of the propel pumps. Clean thefilter bases.

3. Install the new filter elements.


4. Start the engine. Allow the hydraulic oil to warm.Maintain the oil to the level mark on the decalthat is near the sight gauge. If necessary, add oil.

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Hydraulic System Oil Level - Check

i00799435

Hydraulic System Oil Level -Check

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


1. Observe the level of the hydraulic oil in the sightgauge when the oil is warm. Maintain the oillevel to the mark on the decal that is near thesight gauge.

2. If necessary, add oil.


3. In order to add the oil, remove the filler cap. Addthe 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


Refer to Operation and Maintenance Manual, SOSOil Analysis and to Operation and MaintenanceManual, Sampling Interval and Location ofSampling Valve for information that pertains toobtaining an oil sample from the axle.

i01611546

Hydraulic Tank Strainer - Clean

SMCS Code:5056-070-STR


1. Remove the hydraulic oil filler cap and pull thestrainer outward.

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94Maintenance SectionHydraulic 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 platformforward. Refer to the Operation and MaintenanceManual, Cab Tilting or Platform Tilting.

Note:The vent is located on the top of the hydraulicoil tank.

2. Remove the vent on the hydraulic oil tank.

3. Install the new vent.

4. Lower the cab or the platform. Refer to theOperation and Maintenance Manual, Cab Tiltingor Platform Tilting.

i00799708

Indicators and Gauges - Test

SMCS Code: 7450-081



Look for gauges that are broken. Look for indicatorlights that are inoperative. Look for switches thatare broken.

Start the engine.

Sound the horn.

Look for inoperative gauges.

Turn on all of the machine lights. Check for properoperation.


Stop the engine.

Note:When the engine is stopped and the enginestart switch key is turned to theON position, allfour of the indicator lights should illuminate. If theindicator lights do not illuminate, repair the lights orreplace the lights.

Make all necessary repairs before operating themachine.

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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 startswitch is out of adjustment. Be sure the area isclear of all personnel and equipment before per-forming this test.


1. Place the propel lever in the FORWARD position.


2. Hold the engine start switch in the STARTposition. Slowly move the propel lever towardthe STOP position.

3. If the engine starts before you move the propellever to the STOP position. The neutral startswitch requires adjustment. Do not operate themachine 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


The element is shown with debris.

Use a 4C-5084 Filter Cutter or a 175-7546 OilFilter Cutter to cut the filter element open. Spreadapart the pleats and inspect the element for metaland for other debris. An excessive amount of debrisin the filter element can indicate a possible failure.

If metals are found in the filter element, a magnetcan be used to differentiate between ferrous metalsand nonferrous metals.

Ferrous metals can indicate wear on steel parts andon cast iron parts.

Nonferrous metals can indicate wear on thealuminum parts of the engine such as mainbearings, rod bearings, or turbocharger bearings.

Small amounts of debris may be found in the filterelement. This could be caused by friction and bynormal wear. Consult your Caterpillar dealer inorder to arrange for further analysis if an excessiveamount of debris is found.

Using an oil filter element that is not recommendedby Caterpillar can result in severe engine damageto engine bearings, to the crankshaft, and to otherparts. This can result in larger particles in unfilteredoil. The particles could enter the lubricating systemand the particles could cause damage.

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96Maintenance SectionPropel Pump Linkage Rod - Lubricate

i00810362

Propel Pump Linkage Rod -Lubricate

SMCS Code:5462-086-KL


1. Remove the access plate.

Note:Wipe all fittings before lubricating the fittings.


2. Lubricate the two fittings on the propel pumpcontrol linkage.

3. Install the access cover.

i00810426

Radiator Core - Clean

SMCS Code:1353-070-KO

Open the access doors on the left side of themachine.


The radiator core is located at the rear of themachine. Open the access door at the rear of themachine.


Inspect the radiator core for debris. If necessary,clean the radiator.

Compressed air is preferred, but high pressurewater or steam can be used to remove dust andgeneral debris from a radiator. Clean the radiatoraccording to the condition of the radiator.

See Special Publication, SEBD0518, Know YourCooling System for more detailed information aboutcleaning radiator fins.

Close the access doors. Latch the access doors.

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Rollover Protective Structure (ROPS) - Inspect

i00810518

Rollover Protective Structure(ROPS) - Inspect

SMCS Code: 7323-040; 7325-040


Inspect the rollover protective structure (ROPS)for any loose bolts or damaged bolts. Replacethe damaged bolts with original equipment partsonly. Tighten the bolts to a torque of 400 10 Nm(295 7 lb ft).

Note:Apply oil to all ROPS bolt threads beforeinstalling the bolts. Failure to apply the oil to thethreads can result in an improper bolt torque.

Replace the ROPS mounting support if the ROPS

rattles. Replace the ROPS mounting support if theROPS makes noise.

Do not straighten the ROPS or repair the ROPS bywelding reinforcement plates to the ROPS.

Consult your Caterpillar dealer for the repair of theROPS.

i01822494

Seat Belt - Inspect

SMCS Code:7327-040; 7327; 7520

Always check the condition of the seat belt andthe condition of the seat belt mounting hardwarebefore you operate the machine. Replace any partsthat are damaged or worn before you operate themachine.


Typical example

Check the seat belt mounting hardware (1) for wearor for damage. Replace any mounting hardware that

is worn or damaged. Make sure that the mountingbolts are tight.

Check buckle (2) for wear or for damage. If thebuckle is worn or damaged, replace the seat belt.

Inspect the seat belt (3) for webbing that is wornor frayed. Replace the seat belt if the seat belt isworn or frayed.

Contact your Caterpillar dealer for the replacementof the seat belt and mounting hardware.

Note:Within three years of the date of installation or

within five years of the date of manufacture, replacethe seat belt. Replace the seat belt at the datewhich occurs first. A date label for determining theage 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) orwithin 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 determiningthe age of the seat belt is attached to each seat belt.

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98Maintenance SectionSteering Cylinder Ends - Lubricate


(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


Note:Wipe all of the fittings before lubricating thefittings.

There is a fitting for each end of the steeringcylinders. There are four fittings.

i00811133

Steering Pivot Clearance -Adjust

SMCS Code: 4303-025

Refer to the Service Manual for the procedure toadjust the clearance.

i00811601

Tire Inflation - Check

SMCS Code:4203-535-PX


If necessary, inflate the tires.

For normal operating conditions, inflate the tires tothe 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 ofa machine that is ready to work and the machine iswithout attachments. The pressure is based on therated payload, and in average operating conditions.Pressures for each application may vary. Consultyour Caterpillar dealer for more information aboutproper tire inflation pressures.

i00814726

Vibratory Support Oil - Change



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Vibratory Support Oil Level - Check

The vibratory drive gearbox is located on the rightside of the drum.

1. Remove the drain plug. Drain the oil into asuitable 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.


4. Remove the oil filler plug.

5. Add the oil through the filler plug opening. Referto the Operation and Maintenance Manual,Lubricant Viscosities and Refill Capacities.

6. Clean the oil level check plug and install the oillevel check plug. Clean the filler plug and installthe filler plug.

i00814904

Vibratory Support Oil Level -Check



The vibratory drive gearbox is located on the rightside of the drum.

1. Remove the level check plug. Maintain the levelof the oil to the bottom of the level check plugopening.


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 levelcheck plug. Clean the filler plug and install thelevel check plug.

i00814949

Vibratory Support Oil Sample- Obtain

SMCS Code: 5656-008



Refer to the Operation and Maintenance Manual,SOS Oil Analysis. Refer to the Operation andMaintenance Manual, Sampling Interval andLocation of Sampling Valve for information onobtaining the oil sample from the vibratory support.

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100Maintenance SectionWheel Nuts - Tighten

i01612983

Wheel Nuts - Tighten

SMCS Code: 4210-527


Tighten the wheel nuts to a torque of 430 60 Nm(317 44 lb ft).

i00820766

Window Washer Reservoir - Fill

SMCS Code: 7306-544


If the level of the cleaning solution is low, fill the

window washer reservoir. Open the window on theright side of the cab. Through the window, fill thereservoir .

i00820730

Window Wiper -Inspect/Replace

SMCS Code: 7305-040; 7305-510


Inspect the front windshield wiper blade and therear windshield wiper blade. If necessary, replacethe windshield wiper blades.

i00892020

Windows - Clean

SMCS Code: 7310-070

Use commercially available window cleaningsolutions in order to clean the windows. Clean theoutside of the cab windows from the ground unlesshandholds are available.

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KEBU6860-10 M

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