725 AND 730 Articulated Trucks: Maintenance Intervals

SAFETY.CAT.
COM
725 AND 730

ARTICULATED TRUCKS
Maintenance Intervals
Excerpted from Operation & Maintenance Manual (SEBU7814-06-01)
© 2007 Caterpillar
All Rights Reserved
98 SEBU7814-06
Maintenance Section
Maintenance Interval Schedule
i02658699 Cooling System Coolant Level - Check ............... 111

Fuel System Water Separator - Drain ................. 130
Maintenance Interval Schedule Fuel Tank Water and Sediment - Drain ............... 131
Hoist Cylinder Bearings - Lubricate .................... 135
SMCS Code: 1000; 7000 Hydraulic System Oil Level - Check ................... 137
Oscillating Hitch - Lubricate ................................ 141
Ensure that all safety information, warnings and Steering Cylinder Bearings - Lubricate ............... 145
instructions are read and understood before any Suspension and Suspension Cylinder Bearings -
operation or any maintenance procedures are Lubricate ........................................................... 146
performed. Torque Converter and Transmission Oil Level -
Check ................................................................ 150
The user is responsible for the performance of Transfer Gear Oil Level - Check ......................... 154
maintenance, including all adjustments, the use of
proper lubricants, fluids, filters, and the replacement Initial 500 Service Hours
of components due to normal wear and aging. Failure
to adhere to proper maintenance intervals and Engine Valve Lash - Check ................................. 124
procedures may result in diminished performance of Oscillating Hitch - Adjust ..................................... 140
the product and/or accelerated wear of components.
Initial 500 Hours (for New Systems, Refilled
Use mileage, fuel consumption, service hours, or Systems, and Converted Systems)
calendar time, WHICHEVER OCCURS FIRST,
in order to determine the maintenance intervals. Cooling System Coolant Sample (Level 2) -
Products that operate in severe operating conditions Obtain ................................................................ 112
may require more frequent maintenance.
Every 500 Service Hours
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be Belts - Inspect/Adjust/Replace ............................ 102
performed. Brake Pads - Check ............................................ 104
Braking System - Test ......................................... 106
When Required Differential and Final Drive Oil Level - Check ...... 116
Differential and Final Drive Oil Sample - Obtain .. 117
Automatic Lubrication Grease Tank - Fill ............ 100 Engine Crankcase Breather - Clean ................... 120
Battery - Recycle ................................................ 102 Engine Oil Sample - Obtain ................................ 121
Battery or Battery Cable - Inspect/Replace ........ 102 Engine Oil and Filter - Change ........................... 121
Cab Air Filter - Clean/Replace ............................ 107 Fuel System - Prime ........................................... 128
Circuit Breakers - Reset ...................................... 107 Fuel System Primary Filter - Clean/Inspect/
Circuit Breakers - Reset ...................................... 109 Replace ............................................................. 129
Display and Camera - Clean ................................ 117 Fuel System Secondary Filter - Replace ............ 130
Engine Air Filter Primary Element - Clean/ Fuel Tank Cap and Strainer - Clean ................... 131
Replace .............................................................. 118 Hydraulic System Oil Sample - Obtain ............... 138
Engine Air Filter Secondary Element - Replace .. 119 Hydraulic Tank Strainer - Clean/Inspect/
Ether Starting Aid Cylinder - Replace ................. 125 Replace ............................................................. 139
Fuses - Replace .................................................. 132 Torque Converter and Transmission Oil Filter -
Fuses - Replace .................................................. 133 Replace ............................................................. 149
Oil Filter - Inspect ................................................ 140 Torque Converter and Transmission Oil Sample -
Radiator Core - Clean ......................................... 142 Obtain ............................................................... 151
Tire Inflation - Check ........................................... 147 Transfer Gear Oil Sample - Obtain ..................... 155
Window Washer Reservoir - Fill .......................... 156
Window Wiper - Inspect/Replace ........................ 156 Every 1000 Service Hours
Windows - Clean ................................................. 157
Hydraulic System Oil Filter and Screen -
Every 10 Service Hours or Daily Clean/Inspect/Replace ...................................... 136
Oscillating Hitch - Adjust ..................................... 140
Backup Alarm - Test ............................................ 102 Rollover Protective Structure (ROPS) - Inspect .. 143
Brakes, Indicators and Gauges - Test ................. 105 Torque Converter and Transmission Oil -
Engine Oil Level - Check .................................... 120 Change ............................................................. 147
Seat Belt - Inspect .............................................. 145 Transfer Gear Oil - Change ................................ 152
Wheel Nut Torque - Check .................................. 155 Transfer Gear Oil Filter - Replace ....................... 153
Every 50 Service Hours Every 2000 Service Hours

Body Pivot Bearings - Lubricate ......................... 103 Axle Breathers - Clean/Replace ......................... 101
SEBU7814-06 99
Maintenance Section
Maintenance Interval Schedule
Brake System Air - Purge ................................... 105

Differential and Final Drive Oil - Change ............. 115
Engine Valve Lash - Check ................................. 124
Engine Valve Rotators - Inspect ......................... 125
Frame and Body - Inspect .................................. 125
Hydraulic Tank Breather - Clean/Inspect/
Replace ............................................................. 138
Refrigerant Dryer - Replace ................................ 143
Every Year
Brake Accumulator (Service) - Check ................. 103

Cooling System Coolant Extender (ELC) - Add ... 111
Cooling System Coolant Sample (Level 1) -
Obtain ................................................................ 112
Cooling System Pressure Cap - Clean/Replace .. 113
Every 3 Years After Date of Installation or

Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 145

Hydraulic System Oil - Change ........................... 135

Crankshaft Vibration Damper - Inspect ................ 114

Cooling System Coolant (ELC) - Change ........... 109
Cooling System Water Temperature Regulator -
Replace .............................................................. 113
100 SEBU7814-06
Maintenance Section
Automatic Lubrication Grease Tank - Fill
i02601213 • Remove the filler hose and fit the dust cap.
Automatic Lubrication Grease • Place the filler hose back in the hose’s proper
Tank - Fill place in order to ensure that the coupling of the
filler hose remains clean.
(If Equipped)
Note: Every 500 service hours replace the filter or
SMCS Code: 7540-544-TNK every 500 service hours clean the filter for the filler
on the lubrication pump. The filter is behind the
If the yellow LED on the signal lamp is illuminated, connector on the reservoir.
the minimum grease level in the reservoir has been
reached. Note: If the pumping action seems to go heavy,
check the filter behind the coupling for the filler on the
• Ensure that the filler hose is primed with grease in lubrication pump. Gently clean the filter or replace
order to prevent air from being introduced in the the filter. If the filter is damaged, the filter must be
grease reservoir. replaced.
Note: If too much grease is pumped into the reservoir,

the surplus grease will exit the vent at the side of the
lubrication pump. Any air that is introduced during the
filling procedure will also escape via this route.
Note: Due to the slow capability of a hand held

grease gun, the use of a grease gun is not
recommended in order to fill the reservoir.
Periodic Checks
• Check the grease level in the reservoir. Refill the
reservoir on time.
g01074471
Illustration 106
Location of the coupling on the lubrication pump
• Check that the signal lamp is functioning.
• Remove the dust cap from the coupling for the filler. • Check that the duty cycle that is indicated on the
signal lamp is correct for the operating conditions.
• Carefully clean the coupling for the filler and the • Check the lubrication pump for damage and check
coupling on the filler hose. The coupler for the filler
the lubrication pump for leakage.
hose is supplied with each Autolube system.
• Fix the filler hose on the coupling for the filler. • Check the grease lines for damage and check the
grease lines for leakage.
• Check the conditions of the grease points that

are served by the system. Sufficient fresh grease
should be present.
• Check the operation of the system. Perform a

cycle test. Refer to System Operation, Testing and
Adjusting, RENR6739 for more information.
• Clean the lubrication pump and clean the

surroundings of the lubrication pump.
• Every 500 hours replace the filter or every 500

hours clean the filter.
g01076025
Illustration 107
Note: When you use high pressure water or high
The maximum level mark on the lubrication pump
pressure air to clean the machine, do not spray
directly onto the lubrication pump. Water or dirt may
• Fill the reservoir up to the maximum level that is enter the lubrication pump through the de-arating
indicated on the reservoir. openings.
SEBU7814-06 101
Maintenance Section
Axle Breathers - Clean/Replace
Note: The automatic lubrication system reduces

the time and effort that is taken in order to grease
the machine significantly. However, do not neglect
grease points that are not served by the automatic
lubrication system.
Grease Recommendations
Grease should not contain graphite or PTFE. Use the
correct grease in the automatic lubrication system.
The recommended grease for normal working
conditions is 177-3457 Grease.
The use of a partially fluid grease that is above the

maximum temperature that is indicated in Table 17 Illustration 108
g00679632
is not permitted. Use of a partially fluid grease that is
above the maximum indicated temperature can lead Front axle breather (1) is mounted on the left side
to the following. of the front frame.
• Excessive component wear

• A reduction in the efficiency of the system
Table 17
Minimum Maximum
operating operating Prescribed
temperature of temperature of NLGI Grade
the system the system
−25 °C (−13 °F) 80 °C (176 °F) 2
−25 °C (−13 °F) 0 °C (32 °F) 0/1
−25 °C (−13 °F) 80 °C (176 °F) SYNTHETIC 2
g00679631
−25 °C (−13 °F) 0 °C (32 °F) SYNTHETIC 0/1 Illustration 109
Center axle breather (2) is mounted on the right side

i01981266 of the rear frame.
Axle Breathers - Clean/Replace

SMCS Code: 3278-070-BRE; 3278-510-BRE
Park the machine on a level surface. Move the

parking brake control to the ENGAGED position.
Lower the body and shut off the engine.
Install the Steering Frame Lock. Refer to Operation

and Maintenance Manual, “Steering Frame Lock”.
g00679629
Illustration 110
Rear axle breather (3) is mounted on the right side of

the rear frame.
Note: Before you remove the breathers, block the

front frame of the machine.
1. Remove each axle breather.

102 SEBU7814-06
Maintenance Section
Backup Alarm - Test
2. Wash each breather in a clean nonflammable Note: When you replace the batteries, always use
solvent. the same type of battery.
3. Shake each breather until the breather is dry. Use the following procedure in order to isolate the
batteries if any repairs are necessary.
4. Install each breather.
1. Turn the engine start switch to the OFF position.
If any of the axle breathers are damaged, replace the Turn all switches to the OFF position.
damaged breather.
2. Turn the battery disconnect switch to the OFF
Remove the Steering Frame Lock once all the axle position. Remove the key.
breathers are installed. Refer to Operation and
Maintenance Manual, “Steering Frame Lock”. 3. At the battery disconnect switch, disconnect the
negative battery cable that is connected to the
frame.
i02305428
Backup Alarm - Test Note: Do not allow the disconnected battery cable to
contact the disconnect switch.
SMCS Code: 7406-081
4. Disconnect the negative battery cable from the
The backup alarm is on the rear of the machine. terminals of the batteries.
Turn the engine start switch to the ON position in 5. Perform the necessary repairs. Replace the
order to perform the test. cables or the batteries, as needed.
Apply the service brakes. Move the transmission 6. Connect the negative battery cable to the
control lever to the REVERSE position. terminals of the battery.
The backup alarm should start to sound immediately. 7. Connect the negative battery cable at the battery
The backup alarm will continue to sound until the disconnect switch.
transmission control lever is moved to the NEUTRAL
position or to the FORWARD position. 8. Install the key for the battery disconnect switch.
Turn the key to the ON position.
i02039199
i02210445
Battery - Recycle Belts - Inspect/Adjust/Replace
SMCS Code: 1401-561
SMCS Code: 1357-025; 1357-040; 1357-510
Always recycle a battery. Never discard a battery.
Return used batteries to one of the following The engine is equipped with a belt that drives the
locations: alternator and the air conditioner.
Note: The engine is equipped with a belt tensioner

• A battery supplier that automatically adjusts the belt to the correct
tension.
• An authorized battery collection facility
1. Park the machine on a level surface. Engage the
• A recycling facility parking brake. Shut off the engine.
i01951790 2. Raise the hood. Refer to Operation and

Maintenance Manual, “Hood Control”.
Battery or Battery Cable -
Inspect/Replace 3. Remove the pulley guard.
SMCS Code: 1401-510; 1402-510 4. Inspect drive belt (1). Check the belt for wear,
fraying or cracking. If the belt is damaged, replace
Inspect the condition of the cables to the batteries the belt.
and inspect the condition of the batteries.
SEBU7814-06 103
Maintenance Section
Body Pivot Bearings - Lubricate
g01127107 g01126063
Illustration 111 Illustration 112
5. If belt (1) requires replacement, insert a square There is a total of two grease fittings. One grease
drive into the hole in tensioner (3) and turn fitting on the end of each pivot pin. The fittings are
counterclockwise in order to release the tension located at the rear of the machine.
from the belt.
Lubricate the pivot bearings through the grease
6. Remove the belt from the engine. fittings. One or two shots will be required at each
fitting if lubrication is carried out at the recommended
7. In order to Install a new belt, insert a square interval.
drive into the hole in tensioner (3) and turn
counterclockwise.
i02253515
8. Install belt (1) in the following order: tensioner (3),

idler (2), drive pulleys (5), and idler (4).
Brake Accumulator (Service) -
Check
9. Install the pulley guard.
SMCS Code: 4263-535
10. Lower the hood. Refer to Operation and
i02207824 Personal injury or death can result from improper

accumulator charging.
Body Pivot Bearings -
Dry Nitrogen is the only gas approved for use in
Lubricate the accumulator. Charging the accumulator with
oxygen will cause an explosion. This danger will
SMCS Code: 7258-086-BD; 7424-086 not happen if nitrogen cylinders with standard
CGA (Compressed Gas Association, Inc.) Number
Park the machine on a level surface. Ensure that the 580 connections are used.
parking brake is fully engaged. Lower the dump body
and stop the engine. When ordering nitrogen gas, be sure that the cylin-
ders are equipped with CGA Number 580 connec-
Remove the caps and wipe the grease fittings before tions. Do not use color codes or other methods of
lubricant is applied. Install the caps after lubricant identification to tell the difference between nitro-
has been applied. gen and oxygen cylinders
Never use an adapter to connect your nitrogen

charging group to a valve outlet used on both ni-
trogen, oxygen, or other gas cylinders. BE SURE
YOU USE DRY NITROGEN (99.8% purity).
Refer to Systems Operation, Testing and Adjusting,

“Brake Accumulator (Service) - Test and Charge” for
more information.
104 SEBU7814-06
Maintenance Section
Brake Pads - Check
i02310318
Brake Pads - Check

SMCS Code: 4251-535; 4267-535; 4273-535
A tool can be manufactured in order to facilitate

measurements by using the following information.
g01146003
Illustration 113
Fabricate a tool from suitable black steel stock or

suitable mild steel bar. Refer to Illustration 113 and
Table 18.
Table 18
Dimension
235 ± 5 mm
A
(9.25 ± 0.20 inch)
82 ± 0.25 mm
B
(3.23 ± 0.01 inch)(1)
63 ± 0.25 mm
C
(2.48 ± 0.01 inch)(1)
5.0 ± 0.25 mm
D
(0.20 ± 0.01 inch) diameter
10.0 ± 0.25 mm
E
(0.40 ± 0.01 inch) diameter
0.5 mm (0.02 inch)
F
max radius
(1) This dimension is critical to the purpose of the tool.
g01145658
Illustration 114
Typical example
SEBU7814-06 105
Maintenance Section
Brake System Air - Purge
In order to measure the thickness of the brake linings, When the pads are worn, the step on the tool
locate the two holes on the caliper for measuring the will touch the caliper. When this happens, inspect
brake linings. Refer to Illustration 114. Remove any the brake linings. This indicator will show that
plugs from the holes and clean the holes of any dirt. approximately 90% of the life of the brake lining has
been reached. Individual measurements must be
recorded for rotors which have been machined or
excessively worn.
Note: The gauge needs to be used in both holes

because lining pads might not wear evenly.
i02239865
Brake System Air - Purge

SMCS Code: 4250-ABL; 4251
Routine purging of the service brake lines ensures

g01150338 that the system is free of air. Purge the brake groups
Illustration 115
for the center axle and purge the brake groups for
Illustration of the correct method of taking a measurement with the front axle.
the tool
The step on the tool is indicated in the Illustration with an arrow. Refer to the appropriate Systems Operation, Testing
and Adjusting, “Service Brake Air - Purge” for more
information.
i01514959
Brakes, Indicators and Gauges

- Test
SMCS Code: 4251-081; 4267-081; 7000; 7450-081;
7490-081
Before you operate the machine, perform the

following checks and make any necessary repairs.
g01150339
Illustration 116
• Look for broken lenses on the gauges, broken
Illustration of the correct method of taking a measurement with indicator lights, broken switches, and other broken
the tool components in the cab.
The step on the tool is indicated in the Illustration with an arrow.
• Start the engine.
Insert the tool into one of the holes on the caliper
until the end of the tool touches the brake lining or • Look for inoperative gauges.
the step on the tool touches the caliper. Refer to
Illustration 115 and Illustration 116. • Turn on all machine lights. Check for proper
operation.
The tool has two ends of different lengths. Due to
the thickness of the casting, there is approximately • Sound the forward horn.
a 20 mm (0.80 inch) difference between the depth
of the two holes in the casting. Ensure that the • Test the service brakes. Refer to Operation and
correct end of the tool is used in the correct hole for Maintenance Manual, “Braking System - Test”.
measuring the thickness of the brake linings.
• Test the parking brake. Refer to Operation and
Maintenance Manual, “Braking System - Test”.
• Stop the engine.

106 SEBU7814-06
Maintenance Section
Braking System - Test
i01974294
NOTICE
Braking System - Test If the machine moved while testing the service brakes,
contact your Caterpillar dealer.
SMCS Code: 3077-081; 4251-081; 4267-081
Have the dealer inspect and, if necessary, repair the
service brakes before returning the machine to oper-
ation.
Personal injury can result if the machine moves
while testing.
Parking Brake Check
If the machine begins to move during test, reduce
the engine speed immediately and engage the The test for the parking brake must be carried out
parking brake. with the rated load in the body.
Test the service brakes and the secondary steering

The service brake holding ability test determines system on level ground before you carry out this
whether the service brake is functional. This test is procedure.
not intended to measure the maximum brake holding
ability. 1. Drive the machine onto an incline of 15%. The
machine must be pointing down the incline.
The holding ability of the service brakes at a specific
engine rpm will be different for each machine. 2. Engage the service brakes in order to stop
the machine on the incline. The area around
The results of the test should be recorded. The the machine must be clear of personnel and
results should be compared to previous test results obstacles.
and subsequent test results. Use the comparison as
an indication of system deterioration for a particular 3. Move the parking brake control to the ENGAGED
machine. position. Move the transmission control to the N
position.
1. Before you perform the test, ensure that you can
test the brakes on a surface which is level, dry, 4. Shut off the engine.
and clear of obstacles. Fasten your seat belt.
Ensure that the transmission control is in the N 5. Gradually disengage the service brakes.
position and that the parking brake control is in
the ENGAGED position. 6. If the machine moves forward, engage the service
brakes immediately. Start the engine. Disengage
Start the engine and wait until the brake system is the parking brake and drive the machine onto
fully charged. level ground. Shut off the engine.
2. Engage the service brakes. Move the transmission If the machine moved during the test, the parking
control to the 1 position. Move the parking brake brake requires service.
control to the DISENGAGED position.
3. Gradually increase the engine speed until the NOTICE

machine moves forward. Record the engine speed If the machine moved while testing the parking brake,
when the machine moves. inspect the parking brake components for wear or
damage. Repair or replace the worn or damaged park-
Reduce the engine speed immediately and move ing brake components as required before returning the
the parking brake control to the ENGAGED machine to service.
position. Move the transmission control to the N
position. Shut off the engine.
4. If the machine moves at an engine speed below

1200 rpm, the service brakes require service.
SEBU7814-06 107
Maintenance Section
Cab Air Filter - Clean/Replace
i02206819 3. Remove cover (2) and remove the air filter.

Cab Air Filter - Clean/Replace 4. Clean the inside of both air filter housings.
SMCS Code: 7342-070; 7342-510
NOTICE
An air recirculation filter element plugged with dust will
result in decreased performance and service life to the
air conditioner or cab heater.
To prevent decreased performance, clean the filter el-

ement, as required.
Both cab air filters must be serviced at regular

intervals. Operating conditions will influence the
service interval for the cab air filters. Inspect the
filters more often in very dusty conditions. Both cab Illustration 119
g01125369
air filters are located in the right side wall of the cab.
5. Inspect each air filter. If the pleats or the seals are
Replace both air filters if the air filter elements have damaged, replace the air filter.
been in service for one year.
6. If the air filter is not damaged, clean the air filter
1. Park the machine on a level surface. move the with pressurized air. the maximum air pressure for
parking brake control to the ENGAGED position. cleaning is 205 kPa (30 psi).
Lower the dump body and shut off the engine.
Direct pressurized air along the pleats from no
closer than 160 mm (6 inch) from the air filter.
If the air filter is damaged, replace the air filter.
7. Install the air filters. Use the arrows on the air

filters as a guide for correct installation.
8. Install cover (2) and cover (1).
i02206820
Circuit Breakers - Reset

Illustration 117
g01125350 SMCS Code: 1420-529
S/N: B1L1-504
2. Remove cover (1) and remove the air filter.
S/N: B1M1-410
The circuit breaker panel is located to the right of the

operator’s seat. The circuit breaker contains circuit
breakers and fuses for the electrical system.
g01125366
Illustration 118
108 SEBU7814-06
Maintenance Section
Circuit Breakers for the Alternator

and for the Battery
g01130087
Illustration 120
Circuit breakers protect the electrical system from g00677639

damage. Illustration 121
Reset the circuit breaker if a circuit breaker trips. The circuit breakers for the alternator and the battery
Press the button in order to reset the circuit breaker. are located on the front left of the machine under a
If the electrical system is working properly, the button panel on the battery compartment. Circuit breaker
will remain pressed. If the button does not remain (4) for the battery protects the battery from a dead
pressed or if the circuit breaker trips soon after being short. Circuit breaker (5) for the alternator protects
reset, check the appropriate electrical circuit. Repair the alternator from a power surge. Reset the circuit
the electrical circuit, if necessary. breaker if the circuit breaker trips. Press in the button
in order to reset the circuit. If the button does not
Headlamps – 15 amp remain pressed or if the circuit breaker trips soon
after being reset, check the appropriate electrical
circuit. Repair the electrical circuit, if necessary.
Battery (4)
The circuit breaker for the headlamp is located behind

the panel. The circuit breaker resets automatically Alternator (5)
when the fault is corrected.
Heater/Air Conditioner (1) – 15 amp

Circuit Breaker for the Hood
Control Switch
The circuit breaker for the hood control switch
is located with the battery and alternator circuit
Engine Shutdown Switch (2) – 15 amp breakers. Reset the circuit breaker if the circuit
breaker trips. Press in the button in order to reset
the circuit. If the button does not remain pressed or
the circuit breaker trips soon after being reset, check
Start Switch (3) – 10 amp the electrical circuit. Repair the electrical circuit, if
necessary.
Hood Control Switch (6)

SEBU7814-06 109
Maintenance Section
i02379720
Hood Control Switch (3)
SMCS Code: 1420-529
S/N: B1L505-Up
i02234922
S/N: B1M411-Up
Cooling System Coolant (ELC)
Circuit Breakers for the Alternator - Change
and for the Battery SMCS Code: 1350-044-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
Illustration 122
g01188303 touch with your bare hand.
The circuit breakers for the alternator and the battery Do not attempt to tighten hose connections when
are located on the front left of the machine under a the coolant is hot, the hose can come off causing
panel on the battery compartment. Circuit breaker burns.
(1) for the battery protects the battery from a dead
short. Circuit breaker (2) for the alternator protects Cooling System Coolant Additive contains alkali.
the alternator from a power surge. Reset the circuit Avoid contact with skin and eyes.
breaker if the circuit breaker trips. Press in the button
in order to reset the circuit. If the button does not NOTICE
remain pressed or if the circuit breaker trips soon Do not change the coolant until you read and under-
after being reset, check the appropriate electrical stand the cooling system information in Special Pub-
circuit. Repair the electrical circuit, if necessary. lication, SEBU6250, “Caterpillar Machine Fluids Rec-
ommendations”.
Battery (1)
Failure to do so could result in damage to the cooling
system components.
Alternator (2)
NOTICE
Mixing Extended Life Coolant (ELC) with other prod-
ucts reduces the effectiveness of the coolant and
shortens coolant life. Use only Caterpillar products
Circuit Breaker for the Hood or commercial products that have passed the Cater-
Control Switch pillar EC-1 specification for premixed or concentrate
coolants. Use only Caterpillar Extender with Cater-
The circuit breaker for the hood control switch pillar ELC. Failure to follow these recommendations
is located with the battery and alternator circuit could result in the damage to cooling systems com-
breakers. Reset the circuit breaker if the circuit ponents.
breaker trips. Press in the button in order to reset
the circuit. If the button does not remain pressed or
the circuit breaker trips soon after being reset, check
the electrical circuit. Repair the electrical circuit, if
necessary.
110 SEBU7814-06
Maintenance Section
Cooling System Coolant (ELC) - Change
2. Remove the cover from the front of the crankcase

NOTICE guard in order to access the drain valve. Three
Care must be taken to ensure that fluids are contained bolts fasten the cover to the crankcase guard.
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.
If the coolant is dirty or if you observe any foaming Illustration 125

g01127289
in the cooling system, change the coolant before the
recommended interval. 3. Open the drain valve. Allow the coolant to drain
into a suitable container.
Park the machine on a level surface. Ensure that
the parking brake is fully engaged. Lower the dump 4. Close the drain valve.
body and shut off the engine. Do not perform this
procedure until the coolant has fully cooled.
g01126946
Illustration 126
g01126897
Illustration 123 5. The tube assembly that is located near the front
of the engine must be vented in order to ensure
1. Slowly remove the cap in order to gradually relieve proper filling of the cooling system. Failure to vent
any system pressure. this tube assembly may cause the water pump to
cavitate. The tube assembly may be vented in one
of two ways. The tube assembly may be vented
by removing the 154-9024 Sampling Valve.
The tube assembly may also be vented by

purchasing a 177-9343 Fluid Sampling Cap and
Probe Gp from your Caterpillar dealer. Remove
the dust cap from the valve . The probe may be
inserted into the 154-9024 Sampling Valve in
order to vent the tube assembly. The probe must
be held in place.
Add Extended Life Coolant to the coolant tank

until the tube assembly is full.
g01127288
Illustration 124 Install the 154-9024 Sampling Valve or remove
the probe. Secure the dust cap to the valve.
SEBU7814-06 111
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
Add Extended Life Coolant until the level in the i02230995

coolant tank is halfway between the top and the
bottom of the sight glass (2). Cooling System Coolant Level
6. Start the engine. Run the engine until the water
- Check
temperature regulator opens and the coolant level SMCS Code: 1350-535-FLV
stabilizes.
Note: Do not install the cap.
7. Add Extended Life Coolant until the level reaches Pressurized system: Hot coolant can cause seri-
halfway up sight glass (2). Refer to Operation and ous burn. To open cap, stop engine, wait until ra-
Maintenance Manual, “Capacities (Refill)” for the diator is cool. Then loosen cap slowly to relieve
required amount of Extended Life Coolant. the pressure.
8. Inspect the cap. If the cap is damaged, replace Park the machine on a level surface. Ensure that the
the cap. parking brake is fully engaged. Lower the dump body
and shut off the engine.
9. Install the cap.
10. Shut off the engine.
i01865470
Cooling System Coolant

Extender (ELC) - Add
SMCS Code: 1352-544-NL
When a Caterpillar Extended Life Coolant (ELC)

is used, an extender must be added to the cooling
system. See the Operation and Maintenance
Manual, “Maintenance Interval Schedule” for the Illustration 127
g01125467
proper service interval. The amount of extender is
determined by the cooling system capacity. The tank for the cooling system is located at the rear
of the cab.
Table 19
Cooling System Capacity Recommended Amount The tank for the cooling system features a sight glass
of Caterpillar Extender (1).
22 to 30 L (6 to 8 US gal) 0.57 L (20 oz)
Check the cooling system level in the coolant tank.
30 to 38 L (8 to 10 US gal) 0.71 L (24 oz) The coolant level should be maintained halfway
38 to 49 L (10 to 13 US gal) 0.95 L (32 oz)
between the top and the bottom of the transparent
tube of the sight glass on the coolant tank.
49 to 64 L (13 to 17 US gal) 1.18 L (40 oz)
64 to 83 L (17 to 22 US gal) 1.60 L (54 oz)
Add coolant, if necessary. Refer to Operation and
Maintenance Manual, “Cooling System Coolant -
83 to 114 L (22 to 30 US gal) 2.15 L (72 oz) Change” for information on adding coolant.
114 to 163 L (30 to 43 US gal) 3.00 L (100 oz)
163 to 242 L (43 to 64 US gal) 4.40 L (148 oz)
For additional information about adding an extender,

see Special Publication, SEBU6250 or consult your
Caterpillar Dealer.
112 SEBU7814-06
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
i02210457 • Obtain coolant samples directly from the coolant

sample port. You should not obtain the samples
Cooling System Coolant from any other location.
Sample (Level 1) - Obtain
• Keep the lids on empty sampling bottles until you
SMCS Code: 1395-554 are ready to collect the sample.
NOTICE • Place the sample in the mailing tube immediately

after obtaining the sample in order to avoid
Care must be taken to ensure that fluids are contained
contamination.
collect the fluid with suitable containers before open- • Never collect samples from expansion bottles.
nent containing fluids. • 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
products.
Fluids Recommendations” or consult your Caterpillar
dealer.
mandates.
i02210451
Note: Level 1 results may indicate a need for

Level 2 Analysis.
Cooling System Coolant
Sample (Level 2) - Obtain
SMCS Code: 1395-554
NOTICE

g01126946
Illustration 128 products.
Obtain the sample of the coolant as close as possible Dispose of all fluids according to local regulations and
to the recommended sampling interval. In order mandates.
to receive the full effect of S·O·S 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. Illustration 129
g01126946
SEBU7814-06 113
Maintenance Section
Cooling System Pressure Cap - Clean/Replace
Obtain the sample of the coolant as close as possible i02235376

to the recommended sampling interval. Supplies
for collecting samples can be obtained from your Cooling System Water
Caterpillar dealer. Temperature Regulator -
Refer to Operation and Maintenance Manual, Replace
“Cooling System Coolant Sample (Level 1) - Obtain”
for the guidelines for proper sampling of the coolant. SMCS Code: 1355-510
Submit the sample for Level 2 analysis.
Reference: For additional information about coolant Personal injury can result from hot coolant, steam
analysis, refer to Special Publication, SEBU6250, and alkali.
“Caterpillar Machine Fluids Recommendations” or
consult your Caterpillar dealer. At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines
i02234884
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Cooling System Pressure Cap
Remove filler cap slowly to relieve pressure only
- Clean/Replace when engine is stopped and radiator cap is cool
enough to touch with your bare hand.
SMCS Code: 1382-070; 1382-510
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra- Cooling System Conditioner contains alkali. Avoid
diator is cool. Then loosen cap slowly to relieve contact with skin and eyes.
the pressure.
1. Park the machine on a level surface. Ensure that

the parking brake is fully engaged. Lower the
dump body and shut off the engine. Do not perform
this procedure until the coolant has fully cooled.
g01127304
Illustration 131
There are two water temperature regulators. The

water temperature regulator housing is located at the
front of the engine near the alternator.
Illustration 130
g01126897 It is necessary to remove the water temperature
regulator housing in order to replace the water
2. Remove the cap slowly in order to gradually temperature regulators. Refer to Disassembly
relieve any system pressure. and Assembly, SENR9537, “Water Temperature
Regulator - Remove and Install” for a typical
3. Inspect the cap for damage, for foreign material, procedure.
and for deposits. If the cap is damaged, replace
the cap. If the cap is not damaged, clean the cap
with a clean cloth.
4. Install the cap.

114 SEBU7814-06
Maintenance Section
Crankshaft Vibration Damper - Inspect
It is necessary to remove the alternator, the

bracket for the alternator, and the drive belt. These
components must be removed in order to allow the
removal of the water temperature regulator housing.
Refer to Disassembly and Assembly, SENR9537 for
the removal procedures for these components.
Replace the water temperature regulators while the

cooling system is completely drained or while the
cooling system coolant is drained to a level that is
below the water temperature regulator housing.
Refer to Operation and Maintenance Manual,

“Cooling Syatem Coolant - Change” for information
on draining the cooling system. g01127166
Illustration 132
NOTICE The crankshaft vibration damper can be viewed from

Failure to replace the engine’s water temperature reg- the right side of the engine compartment.
ulator on a regularly scheduled basis could cause se-
vere engine damage. Damage to the vibration damper or failure of the
vibration damper will increase torsional vibrations.
These vibrations will result in damage to the
NOTICE crankshaft and other engine components. A
The water temperature regulators may be reused if the deteriorating vibration damper will cause excessive
water temperature regulators are within test specifica- gear train noise at variable points in the speed range.
tions, are not damaged, and do not have excessive
buildup of deposits. Caterpillar recommends replacing the vibration
damper for any of the following reasons.
NOTICE
Since Caterpillar engines incorporate a shunt design • The engine has had a failure because of a broken
cooling system, it is mandatory to always operate the crankshaft.
engine with a water temperature regulator.
• The S·O·S analysis detected a worn crankshaft
Depending on load, failure to operate with a water front bearing.
temperature regulator could result in either an over-
heating or an overcooling condition. • The S·O·S analysis detected a large amount of
gear train wear that is not caused by a lack of oil.
NOTICE Continue to use the crankshaft vibration damper

If the water temperature regulator is installed incor- if none of the above conditions are found or if the
rectly, it will cause the engine to overheat. damper is not damaged.
Refer to the Disassembly and Assembly, SENR9537,

i02235308
“Crankshaft Vibration Damper and Pulley - Remove
and Install” in order to replace the vibration damper.
Crankshaft Vibration Damper
- Inspect
SMCS Code: 1205-040
Park the machine on a level surface. Ensure that the

and shut off the engine. Raise the hood. Refer to
Operation and Maintenance Manual, “Hood Control”.
SEBU7814-06 115
Maintenance Section
Differential and Final Drive Oil - Change
i02232197 6. Repeat Step 2 through Step 4 for the rear right

final drive.
Differential and Final Drive Oil
- Change
SMCS Code: 3258-044; 4050-044
NOTICE

Tools and Shop Products Guide” for tools and supplies Illustration 134
g01125939
products. 7. Remove drain plug (2) and level plug (3) from the
rear axle. Remove the drain plug slowly in order to
Dispose of all fluids according to local regulations and gradually release any system pressure. Allow the
mandates. oil to drain into a suitable container.
1. Operate the machine until the differential oil is 8. Clean the drain plug and inspect the O-ring seal
warm. Park the machine on a level surface. for damage. Lubricate the O-ring seal with gear oil
and install the drain plug.
Note: The drain plug is magnetic. Check the plug

for ferrous particles that may indicate wear of the
differential and final drive components.
9. Start the engine and disengage the parking brake.
g01125937
Illustration 133
2. Slowly move the machine until plug (1) is at the

lowest point on the rear left final drive. Engage the
parking brake and shut off the engine.
3. Wipe the area around plug (1) on the final drive.

g01125942
Remove plug (1). Remove the plug slowly in order Illustration 135
to gradually release any system pressure. Allow
the oil to drain into a suitable container. 10. Slowly move the machine until “Oil Level” mark
(4) on the rear right final drive is horizontal.
4. Clean plug (1) and inspect the O-ring seal for Engage the parking brake and shut off the engine.
damage. Lubricate the O-ring seal with gear oil
and install the plug. 11. Remove plug (1) from the front right final drive
and add oil to the final drive. Refer to Operation
Note: The plug is magnetic. Check the plug for and Maintenance Manual, “Capacities (Refill)” and
ferrous particles that may indicate wear of the Operation and Maintenance Manual, “Lubricant
differential and final drive components. Viscosities”.
5. Start the engine and disengage the parking brake.

116 SEBU7814-06
Maintenance Section
Differential and Final Drive Oil Level - Check
Fill the final drive to the bottom of the plug hole.

Allow the oil to flow along the axle housing and
settle at a common level.
12. Install plug (1).
13. Repeat steps 9 through 12 for the rear left final

drive.
14. Remove level plug (3) from the rear axle. Add oil
to the differential until the differential is full. Refer to
Operation and Maintenance Manual, “Capacities
(Refill)” and Operation and Maintenance Manual,
“Lubricant Viscosities”.
g01293542
15. Install the plug. Illustration 136
Typical example
16. Repeat the procedure for the center differential Some models may have the filler plug toward the right side.
and final drives.
2. Remove differential filler plug (1) and clean the
Repeat the procedure for the front differential and area around the opening.
final drives.
3. Check the oil level. Maintain the oil level to the
17. Start the engine. bottom of the filler plug opening.
18. Operate the machine for a few minutes in order 4. If necessary, add oil. Install the filler plug.
to circulate the oil.
20. Check the oil level of the differential and final

drives. Refer to Operation and Maintenance
Manual, “Differential and Final Drive Oil Level -
Check”.
i02582439

Level - Check
SMCS Code: 3258-535-FLV; 4050-535-FLV g01293543
Illustration 137
Typical Example
1. Park the machine on a level surface and stop the
engine. Perform the following steps on each of Note: The differential and final drives share a
the three axles: common oil compartment. When the machine is
parked on a level surface and when the final drive oil
level mark (3) is horizontal, the final drive filler plug
(2) will be at the same level as the differential filler
plug (1). Allow the oil to fill all of the compartments
before rechecking the oil level.
SEBU7814-06 117
Maintenance Section
Differential and Final Drive Oil Sample - Obtain
i02210940

Sample - Obtain
SMCS Code: 3258-008; 4050-008; 7542-008
Note: Use a sampling gun for obtaining the oil

samples.
g01125892
Illustration 139
8. Wipe the area around plug (3) on the rear axle

housing. Remove the plug and the O-ring seal.
Remove the plug slowly in order to gradually
relieve any system pressure.
9. Obtain an oil sample through the plug hole in the

front axle housing.
g01116160
Illustration 138
10. Clean the plug and check the plug for ferrous
particles that may indicate wear of the differential
1. Park the machine on level ground. Slowly move
and final drive components.
the machine until “Oil Level” mark (1) on the front
right final drive is horizontal. Engage the parking
11. Lubricate the O-ring seal with gear oil. Install the
brake and shut off the engine.
plug and the O-ring seal.
2. Wipe the area around plug (2) on the final drive.
12. Repeat steps 8 through 11 for the center axle and
Remove the plug and the O-ring seal. Remove
the front axle.
the plug slowly in order to gradually relieve any
system pressure.
13. Use S·O·S Oil Analysis in order to monitor
the condition of the differential and final drive
3. Obtain an oil sample through the plug hole in the
components.
final drive.
4. Clean the plug and check the plug for ferrous i02449906
particles that may indicate wear of the final drive
and differential components. Display and Camera - Clean
5. Lubricate the O-ring seal with gear oil. Install the
(If Equipped with Work Area
plug and the O-ring seal. Vision System)
6. Start the engine. SMCS Code: 7347-070; 7348-070
7. Repeat Steps 1 through 6 in order to obtain oil In order to maintain sufficient vision, keep the Work
samples from the final drives on the remaining Area Vision System (WAVS) camera lens and the
five wheels. display clean.
118 SEBU7814-06
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
Display i02206822
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 primary air filter element under the

following conditions.
g01223034 • The indicator for the air filter is illuminated. Refer to

Illustration 140 Operation and Maintenance Manual, “Monitoring
WAVS display System”.
Use a soft, damp cloth in order to clean the display. • The primary air filter element has been in service
The display has a soft plastic surface that can be for 1000 service hours.
easily damaged by an abrasive material. The display
is not sealed. Do not immerse the display with Park the machine on a level surface. Ensure that the
liquid. parking brake is fully engaged. Lower the dump body
Camera 1. Raise the hood.
Refer to the Operation and Maintenance Manual,

“Hood Control”.
g01223051
Illustration 141
The WAVS camera is located on the rear of the machine near
the taillights.
g00681241
Illustration 142
Use a damp cloth or water spray in order to clean
the camera lens. The camera is a sealed unit. The
camera is not affected by high pressure spray. 2. Release three latches (1) and remove air cleaner
cover (2).
The camera is equipped with an internal heater to
help counteract the effects of condensation, snow,
or ice.
Note: For more information on WAVS, refer to

Operation and Maintenance Manual, SEBU8157,
“Work Area Vision System”.
SEBU7814-06 119
Maintenance Section
Engine Air Filter Secondary Element - Replace
6. Inspect the primary air filter element before

installation. If the pleats, the gaskets, or the
seals are damaged, replace the primary air filter
element.
7. Clean the inside of the air cleaner housing.
8. Install a clean, dry primary air filter element.

ensure that the seal is made between the primary
air filter element and the air cleaner housing.
9. Clean the air cleaner cover. Install the air cleaner

cover and engage the latches.
g00681242
10. Lower the hood.
Illustration 143
3. Primary air filter element (3) fits tightly onto air “Hood Control”.
cleaner housing (4). Carefully release the seal by
rocking or twisting the primary air filter element 11. Start the engine. If the indicator for the air filter
and remove the primary air filter element from the is illuminated replace the secondary air filter
air cleaner housing. Avoid touching the primary element.
air filter element against the sides of the air
cleaner housing as this may dislodge dust from Refer to the Operation and Maintenance Manual,
the primary air filter element. “Engine Air Filter Secondary Element - Replace”.
4. Inspect the primary air filter element. If the pleats
or the seals are damaged, replace the primary air i01870108
filter element.
Engine Air Filter Secondary
Element - Replace
Personal injury can result from air pressure. SMCS Code: 1054-510-SE
Personal injury can result without following prop- NOTICE

er procedure. When using pressure air, wear a pro- Always replace the secondary element. Do not at-
tective face shield and protective clothing. tempt to reuse it by cleaning. Engine damage could
result.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
NOTICE
Service the air cleaner only with the engine stopped.
5. If the primary air filter element is not damaged, Engine damage could result.
clean the inside pleats and the outside pleats. The
following method may be used in order to clean
the primary air filter element: Replace the secondary air filter element under these
conditions.
• Pressurized air (Maximum pressure 205 kPa
(30 psi)) • The primary air filter element is serviced for the
third time.
Direct pressurized air along the pleats from no
closer than 160 mm (6 inch) from the primary air • The indicator for the air filter is illuminated after the
filter element. primary air filter element has been serviced. Refer
to Operation and Maintenance Manual, “Monitoring
A primary air filter element may be cleaned for a System”.
maximum of six times. Replace a primary air filter
element after one service year. Park the machine on a level surface. Ensure that the
Note: Do not clean the primary air filter element and shut off the engine.
by bumping or by tapping as this may damage the
primary air filter element. 1. Remove the primary air filter element.
120 SEBU7814-06
Maintenance Section
Engine Crankcase Breather - Clean
Refer to the Operation and Maintenance

Manual, “Engine Air Filter Primary
Element-Clean/Replace”.
g01127512
Illustration 145
2. Loosen hose clamp (1) in order to detach the hose

Illustration 144
g00681252 from the breather. Remove breather (2).
2. Carefully release the seal by rocking or twisting 3. Wash the breather in a clean, nonflammable
secondary air filter element (1). Remove the solvent. Wipe the breather with a clean, dry cloth.
secondary air filter element from air cleaner Replace the breather if the breather is damaged.
housing (2).
4. Inspect the breather seal. If necessary, install a
3. Cover the air inlet opening. Clean the inside of new seal.
the air cleaner housing.
5. Ensure that the breather is dry.
4. Uncover the air inlet opening. Install a new
secondary air filter element. Ensure that the seal 6. Reposition the breather. Fasten the breather to
is made between the secondary air filter element the top of the engine. Tighten hose clamp (1) in
and the air cleaner housing. order to fasten the hose to the breather.
5. Install the primary air filter element. 7. Lower the hood.
Refer to the Operation and Maintenance i02231330

Manual, “Engine Air Filter Primary
Element-Clean/Replace”. Engine Oil Level - Check
6. Install the air cleaner cover and engage the three SMCS Code: 1000-535-FLV
latches.
7. Lower the hood. Refer to Operation and

Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
i02210945 contact skin.
Engine Crankcase Breather -

NOTICE
Clean Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
SMCS Code: 1317-070
Park the machine on a level surface. Ensure that the The engine oil level can be checked when the oil is
parking brake is fully engaged. Lower the dump body cold and the engine is shut off.
The engine oil level should be checked when the oil
1. Raise the hood. is at operating temperature and the engine is running.
Refer to Operation and Maintenance Manual , Note: Perform the cold test before you start the
“Hood Control”. engine.
SEBU7814-06 121
Maintenance Section
Engine Oil Sample - Obtain
1. Raise the hood. Refer to Operation and The sampling valve for the engine oil is located on the
Maintenance Manual, “Hood Control”. right side of the engine on the engine oil filter base.
Refer to Special Publication, SEBU6250, “S·O·S Oil

Analysis” for information that pertains to obtaining a
sample of the engine oil. Refer to Special Publication,
PEHP6001, “How To Take A Good Oil Sample” for
more information about obtaining a sample of the
engine oil.
i02405545
Engine Oil and Filter - Change

SMCS Code: 1318-510
Illustration 146
g01125742
Selection of the Oil Change Interval
2. Remove dipstick (1). The dipstick is located
NOTICE
beneath the hood, adjacent to the secondary fuel
A 500 hour engine oil change interval is available, pro-
filter.
vided that the operating conditions and recommend-
ed multigrade oil types are met. When these require-
3. Clean the dipstick and reinstall the dipstick.
ments are not met, shorten the oil change interval
to 250 hours, or use an S·O·S Services oil sampling
4. Remove the dipstick and check the oil level. The
and analysis program to determine an acceptable oil
oil level should be between the “ADD” and “FULL”
change interval.
marks on the dipstick.
If you select an interval for oil and filter change that is
5. If necessary, remove cap (2) and add oil through
too long, you may damage the engine.
the filler tube.
Refer to Operation and Maintenance Manual, Caterpillar oil filters are strongly recommended.
“Lubricant Viscosities” for the correct oil.
Recommended multigrade oil types are listed in Table
6. Wipe any oil from the dipstick. Reinstall the 20. Do not use single grade oils.
dipstick.
Abnormally harsh operating cycles or harsh
7. Lower the hood. environments can shorten the service life of the
engine oil. Operating with high load factors or with
fuel sulfur levels above 0.3% may require reduced oil
i02210439
drain intervals. Corrosive environments or extremely
Engine Oil Sample - Obtain dusty conditions may require a reduction in engine oil
change intervals from the recommendations in Table
SMCS Code: 1000-008; 7542-008 20.
Operating the engine in the following conditions will

shorten the service life of the engine oil which will
require reduced oil drain intervals:
• Low ambient temperatures

• Short operating durations
• Long idle times
• Altitudes above 1830 m (6000 ft)
• Poor maintenance of air filters or of fuel filters
g01134568
Illustration 147
122 SEBU7814-06
Maintenance Section
See your Caterpillar dealer for more information if this Table 20

product will experience abnormally harsh operating 735, 740 and 740E Articulated Trucks
cycles or harsh environments. Oil Change Interval (1)
Refer to Special Publication, SEBU6250, “Caterpillar Operating Conditions

Machine Fluid Recommendations” for more Severe
information.
Normal(2) High Fuel Altitude
Load Sulfur above
NOTICE Factor from 1830 m
The oil drain intervals specified in table 20 are based Multigrade
Oil Type above 0.3% to (6000 ft)
on the use of premium diesel engine oils. 41 L 0.5%
(10.8 (4)
The preferred oil for attaining the specified intervals is US
Cat DEO Multigrade. gal)per
hour
(3)
Premium oils that meet the Cat ECF-1 (Engine
Crankcase Fluid specification - 1) are second choice Cat DEO
oils. 500 hr 500 hr 500 hr 250 hr(6)
Preferred
Premium oils that meet the API (American Petrole- ECF-1

um Institute) CG-4 category are third choice oils. API 11.0
minimum 500 hr 500 hr 500 hr 250 hr(6)
CG-4 oils must be API licensed, and have a maximum TBN(4)
ash level of 1.35% (wt.) Preferred
ECF-1
TBN(4) 500 hr 500 hr 250 hr(5) 250 hr(6)
below 11.0
API CG-4(7) 500 hr 250 hr(8) 250 hr(8) 250 hr(8)
(1) The standard oil change interval for this engine is 500 hours, if
the operating conditions and recommended oil types that are
listed in this table are met. The traditional oil change interval for
engines is 250 hours. Improvements in the engine allow this
engine oil change interval. This new standard interval is not
permitted for other engines. Refer to the applicable Operation
and Maintenance Manuals for the other engines.
(2) Normal conditions include these factors: Fuel sulfur below
0.3%, altitude below 1830 m (6000 ft), and good air filter and
fuel filter maintenance. Normal conditions do not include high
load factor, harsh operating cycles, or harsh environments.
(3) High load factors can shorten the service life of your engine
oil. Continuous heavy load cycles and very little idle time result
in increased fuel consumption and oil contamination. These
factors deplete the oil additives more rapidly. If the average fuel
consumption of your engine exceed 51 L (13.5 US gal) per
hour, follow the “High Load Factor” recommendations in Table
20. To determine average fuel consumption for your engine,
measure average fuel consumption for a period of 50 to 100
hours. If the application of the engine is changed, the average
fuel consumption may change.
(4) For sulfur content above 0.5%, refer to Special Publication,
SEBU6250, “Caterpillar Machine Fluids Recommendations”,
“Total Base Number (TBN) and Fuel Sulfur Levels for Direct
Injection (DI) Diesel Engines”.
(5) In order to verify an oil change interval of 500 hours, refer to
“Program A” below.
(6) Use “Program B” below to determine an appropriate interval.
(7) ]Premium oils which meet the API (American Petroleum
Institute) CG-4 category are a third choice oil. API CG-4 oils
must be API licensed, and have a maximum ash level of 1.35%
(WT.)
(8) Maximum oil change interval
Adjustment of the Oil Change Interval

Note: Your Caterpillar dealer has additional
information on these programs.
SEBU7814-06 123
Maintenance Section
Program A Procedure for Changing Engine Oil

Verification for an Oil Change Interval of 500 Hours
and Filter
This program consists of three oil change intervals of NOTICE
500 hours. Oil sampling and analysis is done at 250 Care must be taken to ensure that fluids are contained
hours and 500 hours for each of the three intervals during performance of inspection, maintenance, test-
for a total of six oil samples. The analysis includes ing, adjusting and repair of the product. Be prepared to
oil viscosity and infrared (IR) analysis of the oil. If collect the fluid with suitable containers before open-
all of the results are satisfactory, the 500 hour oil ing any compartment or disassembling any compo-
change interval is acceptable for the engine in that nent containing fluids.
application. Repeat Program A if you change the
application of the engine. Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog”, and to Special Publica-
If a sample does not pass the oil analysis, take one tion, GECJ0001, “Cat Shop Supplies and Tools” guide
of these actions: for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
• Shorten the oil change interval to 250 hours.
• Proceed to Program B. mandates.
• Change to a preferred oil type in Table 20. Park the machine on a level surface. Ensure that the
Program B and shut off the engine.
Optimizing Oil Change Intervals Note: Drain the crankcase while the oil is warm and
while the oil is well circulated. This ensures that
Begin with a 250 hour oil change interval. The oil waste particles will be suspended in the oil and that
change intervals are adjusted by increments. Each these particles will be removed as the oil is drained.
interval is adjusted an additional 50 hours. Periodic oil
sampling and analysis is done during each interval.
The analysis includes oil viscosity and infrared (IR)
analysis of the oil. Repeat Program B if you change
the application of the engine.
If an oil sample does not pass the analysis, shorten

the oil change interval, or change to a preferred
multigrade oil type in the listing above.
References
Reference: Special Publication, PEDP7036, “S·O·S

Services”
g01126944
Reference: Special Publication, PEDP7076, Illustration 148
“Understanding the S·O·S Oil Analysis Tests”
1. Remove the cover from the crankcase guard.
Reference: Special Publication, PEHP7052, “Making
the Most of S·O·S Services”
124 SEBU7814-06
Maintenance Section
Engine Valve Lash - Check
Instructions for the installation of the filter are

printed on the side of each Caterpillar spin-on
filter. For non-Caterpillar filters, refer to the
installation instructions that are provided by the
supplier of the filter.
g01126945
Illustration 149
2. Attach a suitable hose to the drain valve.
3. Open the oil drain valve until oil flows from the
hole. Allow the oil to drain into a suitable container. Illustration 151
g01125742
4. Remove the hose from the drain valve. Clean the 10. Remove oil filler cap (2). Fill the crankcase with
oil drain valve and close the oil drain valve. new oil through the filler tube.
5. Raise the hood. Refer to Operation and Refer to Operation and Maintenance Manual,
Maintenance Manual, “Hood Control”. “Lubricant Viscosities” and Operation and
Maintenance Manual, “Capacites (Refill)”.
11. Remove dipstick (1) and then clean the dipstick.

Reinstall the dipstick.
12. Remove the dipstick and check the oil level. The
oil level should be between the “ADD” and “FULL”
marks on the dipstick. Add oil, if necessary.
13. Start the engine and run the engine at low idle
for 1 minute.
14. Repeat steps 11 and 12.
g01134569 15. Close the hood and shut off the engine.
Illustration 150
Note: The engine oil filter is remotely mounted on the i02680477

right side of the engine.
Engine Valve Lash - Check
6. Remove the oil filter with a strap type wrench.
Discard the used oil filter properly. SMCS Code: 1105-535
Refer to the Operation and Maintenance Manual, Engine valve lash adjustments should be made at
“Oil Filter - Inspect”. every 2000 hour interval.
7. Clean the oil filter base. Note: Engine valve lash adjustment on new engines
or on reconditioned engines should be made at 500
8. Apply a thin coat of engine oil to the seal of the hours.
new oil filter.
Maintenance is recommended by Caterpillar for
9. Install the new oil filter by hand. engine valve lash adjustments. The maintenance
for engine valve lash is part of the lubrication and
preventive maintenance schedule in order to provide
maximum engine life.
SEBU7814-06 125
Maintenance Section
Engine Valve Rotators - Inspect
i01284755
NOTICE
Only qualified service personnel should perform this
Ether Starting Aid Cylinder -
maintenance. Refer to the Service Manual or your Replace
Caterpillar Dealer for the complete engine valve lash
adjustment procedure. SMCS Code: 1456-510-CD

dump body and shut off the engine.
Be sure the engine cannot be started while this
maintenance is being performed. To prevent pos- 2. Raise the hood. Refer to Operation and
sible injury, do not use the starting motor to turn Maintenance Manual, “Hood Control”. The ether
the flywheel. starting aid cylinder is located on the left side of
the engine near the primary fuel filter.
Hot engine components can cause burns. Allow
additional time for the engine to cool before mea- 3. Loosen the cylinder retaining clamp. Unscrew and
suring/adjusting engine valve lash clearance. discard the empty ether starting aid cylinder.
4. Remove the gasket. Install a new gasket. A new

NOTICE gasket is provided with each new ether starting
Operation of Caterpillar Engines with improper engine aid cylinder.
valve lash adjustments will reduce the engine efficien-
cy. This reduced efficiency could result in excessive 5. Install a new ether starting aid cylinder. Tighten
fuel usage and/or shortened engine component life. the ether starting aid cylinder hand tight. Tighten
the cylinder retaining clamp securely.
Measure the engine valve lash with the engine
stopped. To obtain an accurate measurement, allow 6. Lower the hood.
at least 20 minutes for the valves to cool to engine
cylinder head and block temperature.
i02251728
i00128925
Frame and Body - Inspect
Engine Valve Rotators - Inspect SMCS Code: 3250-040; 3260-040; 3268-040;
7000-040; 7050-040; 7113-040; 7258-040
SMCS Code: 1109-040
All earthmoving equipment is prone to a high degree
of wear. Regular inspections for structural damage
are necessary.
When inspecting the valve rotators, protective These inspections are particularly important for this
glasses or face shield and protective clothing type of machine as the machines can experience
must be worn, to prevent being burned by hot oil difficult work cycles.
spray.
Regular inspections can minimize the risk of
Inspect the engine valve rotators after the valve accidents. Regular inspections can reduce down
clearances have been set. time.
1. Start the engine and run the engine at low idle. The interval between these inspections depends on
the factors that follow.
2. Watch the top surface of each valve rotator. When
the intake valve or the exhaust valve closes, the • The age of the machine
engine valve rotator should turn slightly.
• The severity of the application
If an intake valve or an exhaust valve fails to rotate,
consult your Caterpillar Dealer. • The loads that have been carried on the machine
• The condition of the haul road
• The amount of routine servicing that has been
carried out
126 SEBU7814-06
Maintenance Section
These inspections should be carried out at intervals Front Frame

no longer than 1000 service hours or six months.
Older machines, or machines that are operating
in severe applications will require more frequent
inspections.
If the machine has been involved in a collision, or

if the machine has been involved in any kind of
accident, the machine must be inspected thoroughly.
Inspect the machine regardless of the date of the last
inspection.
The machine must be clean before the machine is

inspected.
Proper repair of frames and structures requires

specific knowledge of the following subjects.
• Materials that have been used to manufacture the

frame members
• Frame member construction

g00739927
Illustration 152
• Repair techniques that are recommended by the
manufacturer. Inspect the following areas:
Consult your Caterpillar dealer if repairs are • Front engine mountings (1)
necessary. Your Caterpillar dealer is qualified to carry
out repairs on your behalf. • Steering cylinder lugs (2)
All repairs should be carried out by a Caterpillar • Cab mounts (3)
dealer. If you carry out your own repairs, contact
your Caterpillar dealer for advice about proper repair • Suspension towers (4)
techniques.
• Mounting bosses (5) for the front suspension
Particular attention should be given to all welded cylinders
structures. The following items should be thoroughly
inspected for cracks and for defects: • Rear subassembly and hitch lugs (6)
• Front frame
Front Suspension Frame
• Front suspension frame
• Rear frame
• Oscillating hitch
• A-frames
• Dump body
NOTICE
The areas highlighted are of particular importance but
other areas must not be neglected. The entire struc-
ture must be carefully examined.
g01024820
Illustration 153
Inspect the following areas:
• Axle mountings (7)

SEBU7814-06 127
Maintenance Section
• Pivots (8) for the A-frame Rear Frames

• Stabilizer rod (9) and mountings
Oscillating Hitch
g01024822
Illustration 156
g01024833 • Axle mountings (17)

Illustration 154
• The pivots (18) for the A-frames
The entire oscillating hitch should be thoroughly
inspected. Hitch pin lugs (10) and steering cylinder
lugs (11) are particularly important, but all areas of Dump Body
the oscillating hitch must be checked.
Rear Frame
g01024823
Illustration 157

g01024821
Illustration 155
• The mounting brackets (19) for the hoist cylinders
• The mountings (20) for the dump body
• Front plate (12)
• Mountings (13) for the body
• Oscillating hitch tube (14)
• Mounting brackets (15) for the hoist cylinders
• Spindles (16) for the equalizer arms
128 SEBU7814-06
Maintenance Section
Fuel System - Prime
Radiator Mounts i02228009
Fuel System - Prime

SMCS Code: 1250-548
NOTICE

g01134570
Illustration 158 suitable to collect and contain fluids on Caterpillar
products.
• Radiator Mountings (21)
Mounts for the Suspension mandates.
Prime the fuel system in order to fill the fuel filter with
fuel. It is necessary to prime the fuel system after the
fuel filter has been changed.

dump body and shut off the engine.
g00954460
Illustration 159
Check the mounts for cracks and for damage. If

damage is visible, contact your Caterpillar dealer for
more information.
Note: Inspect the mounts for the suspension after

the initial 2000 service hours and every 250 service
hours thereafter. Illustration 160
g01127298
2. Raise the hood. Refer to Operation and

Maintenance Manual, “Hood Control”. The priming
pump for the fuel system is positioned in the
engine compartment on the left side of the engine.
3. Release the plunger by turning the plunger

counterclockwise. Pull out the plunger.
4. Operate the priming pump in order to fill the fuel

filter. Continue to operate the priming pump until
the priming pump resists operation. This indicates
that the fuel filter is full of fuel.
5. Lock the plunger by pushing the plunger toward

the engine and by turning the plunger clockwise.
SEBU7814-06 129
Maintenance Section
Fuel System Primary Filter - Clean/Inspect/Replace
6. Start the engine. Look for leaks around the filter

element.
7. Run the engine at low idle until the engine runs

smoothly.
i02565212
Fuel System Primary Filter -

Clean/Inspect/Replace
SMCS Code: 1260-510; 1260-571
NOTICE
Do not fill fuel filter with fuel before installing the fuel
filter. Contaminated fuel causes accelerated wear to
fuel system parts.
NOTICE
Care must be taken to ensure that fluids are contained Illustration 161
g01296268
ing, adjusting and repair of the product. Be prepared to 4. Insert drain hose (5) into a suitable container.
collect the fluid with suitable containers before open- Open valve (3) in order to drain the fuel from the
ing any compartment or disassembling any compo- filter. Close the valve.
5. Use a strap wrench to remove filter element (1)
Refer to Special Publication, NENG2500, “Caterpillar from the filter base assembly.
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar 6. Detach bowl (2) from the filter element. Properly
products. discard the used filter.
Dispose of all fluids according to local regulations and 7. Clean the filter base assembly.
mandates.
8. Coat the new seal with clean diesel fuel prior to
1. Park the machine on a level surface. Ensure that installation.
dump body and stop the engine. 9. Attach the bowlto the new filter element.
2. Raise the hood. Refer to Operation and 10. Install the new filter element by hand. When the
Maintenance Manual, “Hood Control”. seal contacts the filter base assembly, tighten the
filter by 270 degrees more.
3. Clean the outside of the primary fuel filter element.
Note: The filter element has indicator marks at every
90 degrees.
11. Ensure that the drain hose is routed through hole

(4).
12. Prime the fuel system.

“Fuel System - Prime”.
13. Start the engine and check for leaks.
14. Close the hood.

130 SEBU7814-06
Maintenance Section
Fuel System Secondary Filter - Replace
i02235586 4. Clean the fuel filter base.

Fuel System Secondary Filter - 5. Coat the seal for the new secondary fuel filter with
Replace clean diesel fuel prior to installation.
SMCS Code: 1261-510-SE 6. Install the new secondary fuel filter by hand. Do
not use a tool for installation of the secondary
fuel filter. When the new filter base gasket
NOTICE
contacts the fuel filter base, tighten the secondary
Do not fill the secondary fuel filter with fuel before in-
fuel filter by an additional 270°.
stalling. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
7. Prime the fuel system.
ated wear to fuel system parts.
NOTICE “Fuel System - Prime”.
during performance of inspection, maintenance, test- 8. Start the engine and check for leaks.
collect the fluid with suitable containers before open- 9. Lower the hood.
nent containing fluids. i02589182
Refer to Special Publication, NENG2500, “Caterpillar Fuel System Water Separator

suitable to collect and contain fluids on Caterpillar - Drain
products.
SMCS Code: 1263-543
mandates. NOTICE
Note: Before you replace the secondary fuel filter, ing, adjusting and repair of the product. Be prepared to
the primary fuel filter must be replaced. Refer to the collect the fluid with suitable containers before open-
Operation and Maintenance Manual, “Fuel System ing any compartment or disassembling any compo-
Primary Filter - Clean/Inspect/Replace”. nent containing fluids.
1. Park the machine on a level surface. Ensure that Refer to Special Publication, NENG2500, “Caterpillar
the parking brake is fully engaged. Lower the Dealer Service Tool Catalog” for tools and supplies
dump body and shut off the engine. suitable to collect and contain fluids on Caterpillar
products.
Maintenance Manual, “Hood Control”. Dispose of all fluids according to local regulations and
mandates.

g01127401
Illustration 162
3. Use a strap wrench and remove the secondary

fuel filter. Discard the secondary fuel filter properly.
SEBU7814-06 131
Maintenance Section
Fuel Tank Cap and Strainer - Clean
1. Remove the fuel tank cap.
g01127259
Illustration 165
2. Remove fuel strainer (1).
3. Inspect O-ring seal (2) for damage. Replace the

Illustration 163
g01296353 O-ring seal if the O-ring seal is damaged.
Note: The water separator is located below the 4. Clean the fuel strainer in clean, nonflammable
primary fuel filter element. solvent. If the fuel strainer is damaged, replace
the fuel strainer.
2. Insert drain hose (3) into a suitable container and
open valve (1). Close the valve. 5. Clean the fuel tank cap in nonflammable solvent.
If the fuel tank cap is damaged, replace the fuel
3. Ensure that the drain hose is routed through hole tank cap.
(2).
6. Allow the fuel strainer and the fuel tank cap to dry.
4. Lower the hood.
7. Reinstall the fuel strainer.
i02235442 8. Reinstall the fuel tank cap.

Fuel Tank Cap and Strainer -
Clean i02231905
Fuel Tank Water and Sediment

SMCS Code: 1273-070-Z2; 1273-070-STR
- Drain
parking brake is fully engaged. Lower the dump body SMCS Code: 1273-543-M&S
NOTICE

products.

mandates.
g01127257
Illustration 164
132 SEBU7814-06
Maintenance Section
Fuses - Replace
i02206935
NOTICE
Fill the fuel tank at the end of each day of operation to
Fuses - Replace
drive out moist air and to prevent condensation.
SMCS Code: 1417-510
Do not fill the tank to the top. Fuel expands as it gets S/N: B1L1-504
warm and may overflow.
S/N: B1M1-410
parking brake is fully engaged. Lower the dump body NOTICE
and shut off the engine. Replace fuses with the same type and size only. Oth-
erwise, electrical damage can result.
Drain water and sediment from the fuel tank after the
fuel tank has been filled. Allow the machine to stand If it is necessary to replace fuses frequently, an electri-
for ten minutes before draining the fuel tank. cal problem may exist. Contact your Caterpillar dealer.
The fuses protect the electrical system from damage,

which can be caused by an electrical overload. If
the wire within a particular fuse separates due to an
electrical overload, the circuit will be broken. If the
wire separates, replace the fuse.
g01125850
Illustration 166
The purge screw for the fuel tank is located on the

bottom of the fuel tank. The fuel tank is located on
the right side of the tractor.
1. Remove the fuel tank cap. Illustration 167

g01133613
The fuel tank cap is located on top of the fuel tank. The fuse panel is located on the right side of the seat
for the operator.
2. Open the purge screw until fluid and sediment
starts to flow from the drain hole. 1. Open door (2) in order to access the fuses.
3. Allow the fluid and sediment to flow into a suitable 2. Refer to instructions (1) on the inside of the door
container. in order to select the appropriate fuse.
4. When the flow from the fuel tank is free of water 3. Replace the appropriate fuse.
and sediment, close the purge screw.
Caterpillar Monitoring System – 10 amp
Engine Starting Aid – 10 amp
Seat – 10 amp
SEBU7814-06 133
Maintenance Section
Fuses - Replace
i02640955
Rear Wiper/Washer – 10 amp
Fuses - Replace
SMCS Code: 1417-510
Beacon and Rear Work Lights – 10 amp S/N: B1L505-Up
S/N: B1M411-Up
NOTICE
Replace fuses with the same type and size only. Oth-
erwise, electrical damage can result.
Heated Mirror and Heated seat – 10 amp
If it is necessary to replace fuses frequently, an electri-
cal problem may exist. Contact your Caterpillar dealer.
The fuses protect the electrical system from damage,

which can be caused by an electrical overload. If
Front Wiper/Washer – 10 amp the wire within a particular fuse separates due to an
electrical overload, the circuit will be broken. If the
wire separates, replace the fuse.
Cigar Lighter and Electrical Outlet – 10

amp
Dome Light and Radio – 10 amp
g01188010
Illustration 168
Horn – 10 amp
The fuse panel is located on the right side of the seat
for the operator.
Backup Alarm – 10 amp 1. Open the door to the fuse panel in order to access
the fuses.
2. Refer to the instructions on the inside of the door

Dash Panel Lights and Directional in order to select the appropriate fuse.
Control Signals – 10 amp
3. Replace the appropriate fuse.
Autolube System – 10 amp
Transmission Control – 20 amp

Camera – 7.5 amp
Stop Lights – 10 amp

134 SEBU7814-06
Maintenance Section
Fuses - Replace
Secondary Steering Switch – 7.5 amp Horn – 10 amp
Backup Alarm – 7.5 amp
Differential Lock – 7.5 amp

Engine Start Switch – 7.5 amp
Heated Mirror – 7.5 amp

Caterpillar Monitoring System – 7.5 amp
Rear Work Lights – 7.5 amp

Climate Control – 15 amp
Hoist – 7.5 amp
Secondary Steering Relay – 7.5 amp Transmission Control – 15 amp
Headlights – 15 amp
A4 Actual Gear Switch with Key in ON

position – 7.5 amp Engine Control – 15 amp
Cigar Lighter – 10 amp
Seat – 10 amp
Product Link – 10 amp
Voltage Converter – 10 amp
Directional Control Signals – 10 amp
Front Wiper/Washer – 10 amp
Stop Lights – 10 amp
Rear Wiper/Washer – 10 amp
Dome Light – 7.5 amp

SEBU7814-06 135
Maintenance Section
Hoist Cylinder Bearings - Lubricate
i02207829 i02235414
Hoist Cylinder Bearings - Hydraulic System Oil - Change

Lubricate SMCS Code: 5050-044; 5056-044; 5095-044
SMCS Code: 5102-086-BD
NOTICE
Park the machine on a level surface. Ensure that Care must be taken to ensure that fluids are contained
the parking brake is fully engaged. Raise the body during performance of inspection, maintenance, test-
and install the body prop in order to ensure proper ing, adjusting and repair of the product. Be prepared to
lubrication. collect the fluid with suitable containers before open-
Install the steering frame lock. Refer to Operation nent containing fluids.
products.

mandates.

Before you change the oil, block the front frame of

the machine.
g01126413
Illustration 169
Two grease fittings are located on each hoist cylinder.

One fitting is located at the top of each hoist cylinder.
One fitting is located at the bottom of each hoist
cylinder.
1. Remove the plastic caps from the grease fittings.

Wipe all grease fittings before you lubricate the
hoist cylinder bearings.
2. Lubricate the hoist cylinder bearings via the four

grease fittings.
If regular lubrication is performed at the

recommended interval, only one or two shots of
grease will be required at each grease fitting.
3. Install the plastic caps.
g01133381
Illustration 170
1. Lift the panel that covers the hydraulic tank.

136 SEBU7814-06
Maintenance Section
Hydraulic System Oil Filter and Screen - Clean/Inspect/Replace
9. Check that there is adequate sideways clearance.

Steer the machine fully to the left and steer the
machine fully to the right.
10. Check the oil level. Add oil, if necessary.

“Hydraulic System Oil Level - Check”.
11. Check the filler cap and the seal for damage.
Replace any damaged components. Install the
filler cap.
12. Clean up oil spills.

g01127242
Illustration 171
i02228175
2. Remove filler cap (1). Remove the filler cap slowly
in order to gradually relieve any system pressure. Hydraulic System Oil Filter and
Screen - Clean/Inspect/Replace
SMCS Code: 5056-070-Z3; 5056-510-Z3; 5068-510
NOTICE

Illustration 172
g01127252 suitable to collect and contain fluids on Caterpillar
products.
3. Drain plug (2) is located beneath the tank.
Remove the drain plug. Install 6B-3156 Pipe mandates.
Nipple in order to unseat the drain valve. Allow the
oil to drain into a suitable container.
4. Remove the pipe nipple. Inspect the drain plug and

the seal for damage. If the drain plug or the seal
are damaged, replace the damaged components.
Install the drain plug and the seal.
5. Fill the tank with new oil through the filler tube.

“Lubricant Viscocities” and Operation and
Maintenance Manual, “Capacities (Refill)”.
6. Start the engine and run the engine at low idle.
7. Check that there is adequate vertical clearance.
8. Raise the dump body and lower the dump body.
g01133448
Illustration 173
SEBU7814-06 137
Maintenance Section
Hydraulic System Oil Level - Check
The oil filter elements and the screen are located

inside tank (1). Lift panel (2) in order to access
these components. Reposition the panel once these
components have been serviced.
g00686999
Illustration 176
4. There are two filter elements (8) within screen

(9). Remove both elements and discard both filter
Illustration 174
g01127691 elements.
1. Remove filler cap (3). Remove the filler cap slowly 5. Wash the screen in clean nonflammable solvent.
in order to gradually relieve any system pressure. Inspect the screen for damage. If necessary,
replace the screen. Allow the screen to dry.
2. Unscrew bolt (4) and lift cover (5). The screen
assembly is fastened to the cover. 6. Install two new filter elements into the clean
screen.
7. Install cotter pin (6) and washer (7) on bolt (4).
8. Install bolt (4) and cover (5).
9. Replace filler cap (3).
i02207745
Hydraulic System Oil Level -

Check
SMCS Code: 5050-535-FLV; 5056-535-FLV;
5095-535-FLV
NOTICE
g00686996 collect the fluid with suitable containers before open-
Illustration 175 ing any compartment or disassembling any compo-
3. Remove cotter pin (6) and washer (7) from bolt (4).
This will allow the removal of the filter elements Refer to Special Publication, NENG2500, “Caterpillar
from the inside of the screen. Tools and Shop Products Guide” for tools and supplies
products.

mandates.

the parking brake is fully engaged.
138 SEBU7814-06
Maintenance Section
Hydraulic System Oil Sample - Obtain
2. Shut off the engine and allow the level of the oil i02228019
to stabilize.
Hydraulic System Oil Sample
- Obtain
SMCS Code: 5050-008; 7542-008

Install the steering frame lock. Refer to Operation

g01133455
Illustration 177
3. Check the oil level on sight glass (1). The sight

glass is located within panel (2) on the left side of
the machine.
g01127254
Illustration 179
The sampling valve for the hydraulic system oil is

located on the left side of the machine behind the cab.
Refer to Special Publication, SEBU6250, “S·O·S Oil

Analysis” for information that pertains to obtaining
a sample of oil. Refer to Special Publication,
PEHP6001, “How To Take A Good Oil Sample” for
more information about obtaining a sample of oil.
i02235389
Hydraulic Tank Breather -

Illustration 178
g01127255
4. The oil must be at the highest level (2) when the SMCS Code: 5056-040-BRE; 5056-070-BRE;
oil is at operating temperature. When the oil is 5056-510-BRE
cold the oil must be halfway between the highest
level and the lowest level (3) on the sight glass. The tank is located on the left side of the tractor.
Maintain the oil at these levels.
If necessary, add oil through the oil filler tube.

“Hydraulic System Oil - Change” and Operation
and Maintenance Manual, “Lubricant Viscocities”.
SEBU7814-06 139
Maintenance Section
Hydraulic Tank Strainer - Clean/Inspect/Replace
i02228026
Hydraulic Tank Strainer -

SMCS Code: 5056-040-STR; 5056-070-STR;
5056-510-STR
NOTICE

products.
g01133381
Illustration 180 Dispose of all fluids according to local regulations and
mandates.
1. Lift the panel that covers the hydraulic tank.
g01127233
Illustration 181
2. Remove filler cap (2). Remove the filler cap slowly

in order to gradually relieve any system pressure.
3. Unscrew breather (1). Remove the breather from

the machine.
4. Clean the breather in nonflammable solvent.

Shake the breather until the breather is dry.
g01133381
Illustration 182
5. Inspect the breather for damage. If the breather is
damaged, replace the breather. The strainer is located inside the filler tube for the
tank. The filler tube is located on top of the tank on
6. Install the clean breather. the left side of the machine. Lift the panelthat covers
the hydraulic tank in order to access the filler tube.
7. Install the filler cap and close cover (1). Reposition this panel once the strainer has been
cleaned.
140 SEBU7814-06
Maintenance Section
Oil Filter - Inspect
Use a filter cutter to cut the filter element open.

Spread apart the pleats and inspect the element for
metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
failure.
If metals are found in the filter element, a magnet can

be used to differentiate between ferrous metals and
nonferrous metals.
Ferrous metals can indicate wear on steel parts and

on cast iron parts.
Nonferrous metals can indicate wear on the

g01127485
aluminum parts of the engine such as main bearings,
Illustration 183 rod bearings, or turbocharger bearings.
1. Remove filler cap (1). Small amounts of debris may be found in the filter
element. This could be caused by friction and by
2. Remove retaining ring (2) and remove strainer (3) normal wear. Consult your Caterpillar dealer in order
from the hydraulic filler tube. to arrange for further analysis if an excessive amount
of debris is found.
3. Wash the strainer in nonflammable solvent. Allow
the strainer to dry before the strainer is reinstalled. Using an oil filter element that is not recommended
by Caterpillar can result in severe engine damage
If the strainer is damaged, replace the strainer. to engine bearings, to the crankshaft, and to other
parts. This can result in larger particles in unfiltered
4. Inspect the filler cap and the gasket which is oil. The particles could enter the lubricating system
inside of the filler cap. Replace any damaged and the particles could cause damage.
components.
5. Install the strainer and the retaining ring. i02243702
6. Install the filler cap. Oscillating Hitch - Adjust

SMCS Code: 7113-025
i02106227
1. Relieve the tension from the oscillating hitch.
Oil Filter - Inspect Place a large block of timber behind the rear
wheels of the machine and reverse the machine
SMCS Code: 1308-507; 3067-507; 5068-507 against the block.
Inspect a Used Filter for Debris 2. Install the steering frame lock. Refer to Operation
Adjusting Hitch Pin Clearance

1. To relieve the downward force, position a hydraulic
jack under the tractor portion of the hitch and
slightly raise the hitch.
g00100013
Illustration 184
The element is shown with debris.
SEBU7814-06 141
Maintenance Section
Oscillating Hitch - Lubricate
2. Reposition locking plate (5) against thrust flange

(3). Engage both dowels (7) into two of the holes
in thrust flange (3).
3. Insert a 3/4 inch square drive through the hole in

locking plate (5). The square drive will prevent
locking plate (5) from rotating clockwise.
4. Use a suitable wrench on the square drive in order

to turn thrust flange (5) clockwise until all end play
has been removed.
5. If necessary, turn the thrust flange

counterclockwise in order to line up the
g00738671
holes. Insert the square drive into the hole on
Illustration 185 locking plate (5) in order to rotate the thrust flange
counterclockwise. Rotate the thrust flange as far
2. Loosen jam nuts (1). Turn adjusting screws (2) as the first correct hole alignment.
clockwise onto the top of the thrust ring. Turn
the adjustment screws evenly in order to take up 6. Remove the square drive and reposition locking
excessive clearance. Do not overtighten the plate (5) and bolts (4).
screws.
7. Remove the hydraulic jack.
3. Tighten jam nuts (1).
8. Remove the steering frame lock.
Adjusting the Thrust Plate
i02231962
Oscillating Hitch - Lubricate

SMCS Code: 7113-086
NOTICE
Check that lines attached to remote grease fittings are
undamaged. If the lines are split grease will not reach
the bearings or pins. Machine damage will result.
The hitch bearings must be lubricated regularly. Rapid

wear will result from inadequate lubrication.
g00738672
Illustration 186 Park the machine on a level surface. Ensure that the
1. Remove two bolts (4) and remove locking plate and stop the engine.
(5).
If regular lubrication is carried out at the
recommended interval, the fittings for the oscillating
hitch pins should only take one or two shots of
grease. As many as twenty shots of grease may
be used in order to lubricate the bearings for the
oscillating hitch.
1. Install the steering frame locks. Refer to Operation

2. Before you lubricate the fittings, wipe the fittings in

order to clean the fittings.
g00742918
Illustration 187
142 SEBU7814-06
Maintenance Section
Radiator Core - Clean
g01125855 g01125452
3. Lubricate the hitch bearings through fittings (1). To access the radiator, cover (1) needs to be
Fitting (2) is initially used to fill the cavity between removed. The cover is held in place by four bolts .
the two hitch bearings. This fitting does not require
regular lubrication. You can use compressed air, high pressure water
or steam to remove dust and other debris from the
radiator core. However, the use of compressed air
is preferred.
Refer to Special Publication, SEBD0518, “Know

Your Cooling System” for the complete procedure for
cleaning the radiator core.
g01125856
Illustration 189
4. Lubricate the hitch pins through two fittings (3).
5. Remove the steering frame locks.
i02206939
Radiator Core - Clean

SMCS Code: 1353-070-KO
Personal injury can result from air pressure.
Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.
SEBU7814-06 143
Maintenance Section
Refrigerant Dryer - Replace
i01836475 Remove the panel in order to gain access to the

in-line refrigerant dryer. The panel is held in place by
Refrigerant Dryer - Replace seven bolts and washers, which should be retained.
SMCS Code: 7322-510 Note: One of the bolts is located under cover (2).
Refer to Service Manual, SENR5664, “In-Line

Refrigerant Dryer - Remove and Install” for the
Personal injury can result from contact with refrig- replacement procedure of the in-line refrigerant dryer.
erant.
Note: When you operate the machine in a climate
Contact with refrigerant can cause frost bite. Keep with high humidity, replace the in-line refrigerant dryer
face and hands away to help prevent injury. after every 1000 service hours or 6 months.
Protective goggles must always be worn when re-

i01400959
frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant. Rollover Protective Structure
Always use precaution when a fitting is removed. (ROPS) - Inspect
Slowly loosen the fitting. If the system is still un-
der pressure, release it slowly in a well ventilated SMCS Code: 7323-040; 7325-040
area.
NOTICE
Personal injury or death can result from inhaling Do not attempt to straighten the ROPS structure. Do
refrigerant through a lit cigarette. not repair the ROPS by welding reinforcement plates
to the structure.
Inhaling air conditioner refrigerant gas through a
lit cigarette or other smoking method or inhaling If there are any cracks in the welds, in the castings, or
fumes released from a flame contacting air con- in any metal section of the ROPS, consult your Cater-
ditioner refrigerant gas, can cause bodily harm or pillar dealer for repairs.
death.
Do not smoke when servicing air conditioners or

wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to prop-

erly remove the refrigerant from the air condition-
ing system.
Park the machine on a level surface. Engage the

parking brake. Lower the dump body and shut off
the engine.
g00738669
Illustration 192
The ROPS is held in position by four mounting bolts

(1), four pins (2) and four rubber mounts (3). One
mounting bolt, one pin and one rubber mount is
located on each corner of the ROPS.
Carry out the following steps in order to inspect the

ROPS:

g00737759
Illustration 191 the engine.
The in-line refrigerant dryer is located behind panel 2. Install the steering frame lock. Refer to Operation
(1) on the right side of the cab. and Maintenance Manual, “Steering Frame Lock”.
144 SEBU7814-06
Maintenance Section
Rollover Protective Structure (ROPS) - Inspect
3. Raise the hood in order to access the front ROPS 6. Remove cover (7) that covers the radiator on the
mountings. Refer to Operation and Maintenance right side of the machine and retain the bolts. This
Manual, “Hood Control”. will enable removal of panel (8) later.
g00738305 g00738540
4. Remove cover (4) at the left side rear of the cab 7. Remove panel (8) on the right side of the cab and
by removing four bolts (5) and retaining the four retain the bolts.
bolts. This will enable access to inspect the left
side rear mounting. Note: One of the bolts is located under cover (9).
Remove fender panel (10) and retain the bolts.
8. Inspect the following items: mounting bolts (1),

pins (2), and rubber mounts (3). Replace any
damaged pins, bolts or rubber mounts with original
equipment parts.
9. Inspect the ROPS for bolts that are loose or

damaged. Bolts that are loose, damaged or
missing should be replaced by original equipment
parts only.
10. Tighten mounting bolts (1) to a torque of

900 ± 100 N·m (664 ± 74 lb ft).
g00738528
Illustration 194
11. Use the bolts that were retained earlier in order to
5. Remove tank cover (6) on the fuel tank and retain secure the covers and panels. Secure the covers
the bolts. This will enable removal of fender panel and panels in the following order: fender panel
(10) later. (10), panel (8), cover (9), cover (7), tank cover (6),
and cover (4).
12. Close the hood. Refer to Operation and

13. Remove the steering frame lock. Refer to

Operation and Maintenance Manual , “Steering
Frame Lock”.
g00738535
Illustration 195
SEBU7814-06 145
Maintenance Section
Seat Belt - Inspect
i02429589 i02429594
Seat Belt - Inspect Seat Belt - Replace

SMCS Code: 7327-040 SMCS Code: 7327-510
Always check the condition of the seat belt and the Within three years of the date of installation or within
condition of the seat belt mounting hardware before five years of the date of manufacture, replace the
you operate the machine. Replace any parts that are seat belt . Replace the seat belt at the date which
damaged or worn before you operate the machine. occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.
g00932801
Illustration 197 g01152685
Illustration 198
Typical example
(1) Date of installation (retractor)
(2) Date of installation (buckle)
Check the seat belt mounting hardware (1) for wear (3) Date of manufacture (tag) (fully extended web)
or for damage. Replace any mounting hardware that (4) Date of manufacture (underside) (buckle)
is worn or damaged. Make sure that the mounting
bolts are tight. Consult your Caterpillar dealer for the replacement of
the seat belt and the mounting hardware.
Check buckle (2) for wear or for damage. If the buckle
is worn or damaged, replace the seat belt. If your machine is equipped with a seat belt
extension, also perform this replacement procedure
Inspect the seat belt (3) for webbing that is worn or for the seat belt extension.
frayed. Replace the seat belt if the seat belt is worn
or frayed.
i02233289
Consult your Caterpillar dealer for the replacement of Steering Cylinder Bearings -
the seat belt and the mounting hardware.
Lubricate
Note: Within three years of the date of installation or
within five years of the date of manufacture, replace SMCS Code: 4303-086-BD
the seat belt. Replace the seat belt at the date which
occurs first. A date label for determining the age of NOTICE
the seat belt is attached to the seat belt, the seat belt Check that the lines attached to all the remote grease
buckle, and the seat belt retractor. fittings are undamaged. If the grease lines are split,
grease will not reach the components that require lu-
If your machine is equipped with a seat belt bricating. Machine damage will result.
extension, also perform this inspection procedure for
the seat belt extension.
Park the machine on a level surface. Ensure that
the parking brake is fully engaged. Lower the dump
body and stop the engine. Install the steering frame
lock. Refer to Operation and Maintenance Manual,
“Steering Frame Lock”.
146 SEBU7814-06
Maintenance Section
Suspension and Suspension Cylinder Bearings - Lubricate
If regular lubrication is carried out at the i02234187

recommended intervals, only one or two shots of
grease will be required at each fitting. If more than Suspension and Suspension
two shots of grease per fitting are required, the lines
may be split or damaged, and grease will not reach
Cylinder Bearings - Lubricate
the steering cylinder pins. SMCS Code: 7200-086-BD; 7201-086-BD
1. Remove the plastic caps and clean the fittings
before you apply grease. Reinstall the plastic caps NOTICE
once grease has been applied. Check that the lines attached to all the remote grease
fittings are undamaged. If the grease lines are split,
grease will not reach the components that require lu-
bricating. Machine damage will result.

the engine. Install the steering frame lock. Refer
to Operation and Maintenance Manual, “Steering
Frame Lock”.
If regular lubrication is performed at the recommended

intervals, only one or two shots of grease will be
required at each fitting.
g01126471
1. Clean all the fittings by wiping before you lubricate
Illustration 199 the fittings.
2. Lubricate the front steering cylinder bearings Note: The fittings are located behind caps which
through the fittings on the panel. require removing in order to access the fittings.
g01126474
g01126573
3. Lubricate the rear steering cylinder bearings 2. Lubricate the front suspension cylinder bearings
through fittings on the cylinders. through fittings (1). Lubricate the spherical bearing
on the front suspension a-frame through fitting (2).
4. Remove the steering frame locks.
Note: The fittings for lubrication of the front
suspension are located at the rear of the tractor on
the left side.
SEBU7814-06 147
Maintenance Section
Tire Inflation - Check
• Operation and Maintenance Manual, “Tire Shipping

Pressure”
• Operation and Maintenance Manual, “Tire Inflation

Pressure Adjustment”
i02236058
Torque Converter and

Transmission Oil - Change
SMCS Code: 3030-044-OC; 3101-044-OC
Illustration 202
g01126574 NOTICE
3. Lubricate the spherical bearings on the rear during performance of inspection, maintenance, test-
suspension a-frames through fittings (3). ing, adjusting and repair of the product. Be prepared to
Note: The fittings for lubrication of the spherical ing any compartment or disassembling any compo-
bearings on the rear suspension a-frames are located nent containing fluids.
at the front of the trailer on the left side.
4. Install the caps to the fittings. Tools and Shop Products Guide” for tools and supplies
5. Remove the steering frame lock. Refer to products.
Operation and Maintenance Manual, “Steering
Frame Lock”. Dispose of all fluids according to local regulations and
mandates.
i00062438
Tire Inflation - Check

SMCS Code: 4203-535-AI injury. Do not allow hot oil or hot components to
contact skin.
Operate the machine until the torque converter and

transmission oil is warm. Park the machine on a level
surface. Engage the parking brake. Lower the dump
body and shut off the engine.

The oil level dipstick is integral with the oil filler cap
for the torque converter and transmission oil. The
oil filler cap is located near the air cleaner housing.
g00103147
Illustration 203
Measure the air pressure on each tire. Consult your

Caterpillar dealer for the correct load rating and for
the correct operating pressures.
If necessary, inflate the tires. Refer to the following

additional information about tire inflation:
• Operation and Maintenance Manual, “Tire Inflation

with Nitrogen”
148 SEBU7814-06
Maintenance Section
Torque Converter and Transmission Oil - Change
4. Clean the area around drain plug (5).
5. Remove the drain plug and the O-ring seal and

retain the drain plug and the O-ring seal. Allow the
oil to drain into a suitable container.
6. Inspect the O-ring seal for the drain plug. If

necessary, replace the O-ring seal. Lubricate the
O-ring seal with transmission oil. Install the O-ring
seal and the drain plug.
7. Remove the oil filter for the torque converter and

transmission oil. Discard the oil filter. Install a
new oil filter. Refer to Operation and Maintenance
g01126900
Manual, “Torque Converter and Transmission Oil
Illustration 204 Filter - Replace”.
2. Clean the area around filler cap (1) and filler tube 8. Fill the transmission with new oil through filler
(2). Turn the handle on the dipstick in order to tube (2). Fill the transmission to the “COLD
remove the dipstick. Remove the dipstick in order SAFE START” range on the oil level dipstick.
to allow the oil to drain. Refer to the Operation and Maintenance Manual,
“Capacities (Refill)”, Operation and Maintenance
Note: Before you change the oil, block the front Manual, “Lubricant Viscosities” and Operation
frame of the machine. and Maintenance Manual, “Torque Converter and
Transmission Oil Level - Check”.
9. Guide the dipstick down the filler tube and turn the
handle on the dipstick in order to make the seal
between the filler tube and the filler cap.
10. Start the engine. Run the engine at low idle.

Inspect the transmission for leaks.
11. Ensure that the parking brake is engaged.

Engage the service brakes. Slowly operate the
transmission control in order to circulate the oil.

g01127725
Illustration 205
13. Replace Plate (3).
3. Remove plate (3) in order to access the drain plug
for the torque converter and transmission oil. 14. Wait for five minutes before removing dipstick (1).
Turn the handle on the dipstick in order to remove
Note: Plate (3) is located on the right side of the dipstick.
transmission guard (4) in front of the front axle.
15. Clean the dipstick by wiping.
16. Install the dipstick fully.
17. Check the oil level on the COLD SAFE START

side of the dipstick. The engine can be started
if the oil is anywhere within the shaded area. If
necessary, add oil.
18. Lower the hood.
19. Start the engine. Operate the machine until the

temperature of the oil is at normal operating
temperature.
Illustration 206
g01127726 20. Raise the hood.
SEBU7814-06 149
Maintenance Section
Torque Converter and Transmission Oil Filter - Replace
21. Check the torque converter and transmission

oil level on the “FULL HOT LOW IDLE” side of
the dipstick. Refer to Operation and Maintenance
Manual, “Torque Converter and Transmission Oil
Level - Check”. If necessary, add oil.
23. Close the hood.
i02228027
Torque Converter and

Transmission Oil Filter - g01127612
Replace Illustration 207
1. Remove the cover in order to access the oil filter

SMCS Code: 3067-510; 3101-510-FI cover.
NOTICE

products.
Dispose of all fluids according to local regulations and g01127613

mandates. Illustration 208
2. Clean the area around drain plug (3). Remove the

drain plug and the O-ring seal and retain the drain
plug and the O-ring seal. Allow the oil to drain into
Hot oil and hot components can cause personal a suitable clean container.
contact skin. Note: Approximately 4.5 L (1.2 US gal) will drain from
the transmission when drain plug (3) is removed.
Park the machine on a level surface. Engage the 3. Remove oil filter cover (2). Remove the O-ring
parking brake. Lower the dump body and shut off seal and retain the O-ring seal.
the engine.
Note: Note the orientation of cover (2). The cover
Note: Before you remove the filter, block the front must be installed in the position.
frame of the machine.
4. Remove the nut and the washer that secures the
oil filter to the transmission. Remove the oil filter
and discard the oil filter.
5. Fit a new oil filter. Fit the washer and the nut in
order to secure the oil filter to the transmission.
6. Inspect the O-ring seal for the oil filter cover. If

seal and oil filter cover (2).
150 SEBU7814-06
Maintenance Section
Torque Converter and Transmission Oil Level - Check
7. Inspect the O-ring seal for drain plug (3). If

seal and install the drain plug.
8. Top up the torque converter and transmission

oil level with the correct oil. Refer to Operation
and Maintenance Manual, “Torque Converter and
Transmission Oil Level - Check” and Operation
and Maintenance Manual, “Lubricant Viscosities”.
9. Check oil filter cover (2) and drain plug (3)

for leaks. If oil leakage is evident, repeat the
replacement procedure.
g01126900
10. Replace the cover on the transmission guard. Illustration 209
3. Wipe oil filler cap (1) and oil filler tube (2).
i02207767
Note: The oil level dipstick is integral with the oil filler
Torque Converter and cap for the transmission oil. Oil filler tube (2) for the
Transmission Oil Level - torque converter and transmission oil is located on
the left side of the machine near the air cleaner.
Check
4. Turn the handle on the oil level dipstick in order to
SMCS Code: 3030-535-FLV; 3101-535-FLV remove the dipstick. Remove the oil level dipstick.
NOTICE 5. Clean the dipstick by wiping.

during performance of inspection, maintenance, test- 6. Install the dipstick fully.
collect the fluid with suitable containers before open- 7. Remove the dipstick.

products.

mandates.
The oil level should be checked before starting the

engine.
1. Park the machine on a level surface. Engage the Illustration 210

g00740027
parking brake and lower the dump body.
Note: The oil level dipstick is marked “COLD SAFE
2. Raise the hood. Refer to Operation and START” on one side. The oil level dipstick is marked
Maintenance Manual, “Hood Control”. “FULL HOT LOW IDLE” on the other side.
8. Check the oil level on the “COLD SAFE START”

side of the dipstick.
The engine can be started if the oil is anywhere

within the shaded area. Do not add oil if the
level is toward the bottom of the “COLD
SAFE START” shaded area. An oil level that is
anywhere in this range is normal.
SEBU7814-06 151
Maintenance Section
Torque Converter and Transmission Oil Sample - Obtain
9. Guide the dipstick down the filler tube and turn the i02228028
handle on the dipstick in order to make the seal
between the filler tube and the filler cap. Torque Converter and
10. Lower the hood.
Transmission Oil Sample -
Obtain
temperature of the oil is at normal operating SMCS Code: 3030-008; 3101-008; 7542-008
temperature.
NOTICE
12. Park the machine on a level surface. Engage the Care must be taken to ensure that fluids are contained
parking brake. during performance of inspection, maintenance, test-
13. Raise the hood. Wait for five minutes before collect the fluid with suitable containers before open-
removing dipstick (1). Turn the handle on the ing any compartment or disassembling any compo-
dipstick in order to remove the dipstick. nent containing fluids.
Note: The shaded area on the side of the oil level Refer to Special Publication, NENG2500, “Caterpillar
dipstick that is marked “FULL HOT LOW IDLE” Tools and Shop Products Guide” for tools and supplies
indicates the correct transmission oil level. Refer to suitable to collect and contain fluids on Caterpillar
illustration 210. products.
14. Clean the dipstick by wiping. Dispose of all fluids according to local regulations and
mandates.
16. Remove the dipstick and check the oil level.
17. Check the oil level on the “FULL HOT LOW IDLE” Hot oil and hot components can cause personal
side of the dipstick. Maintain the oil level within injury. Do not allow hot oil or hot components to
the shaded area on the dipstick. If necessary, add contact skin.
oil through filler tube (2). Refer to Operation and
Maintenance Manual, “Lubricant Viscosities” and
Operation and Maintenance Manual, “Capacities
(Refill)”.
18. Guide the dipstick down the filler tube and turn
the handle of the dipstick in order to make the seal
19. Lower the hood.
g01127660
Illustration 211
Remove the plate on the left side of the transmission

guard in order to access the sampling port.
152 SEBU7814-06
Maintenance Section
Transfer Gear Oil - Change
g01127662 g00740248
The sampling valve is located on the left side of the Drain plug (1) for the transfer gear is located on the
transmission. bottom of the transfer gear case.
Refer to Special Publication, SEBU6250, “S·O·S Oil Note: Before you change the oil, block the front
Analysis” for information that pertains to obtaining a frame of the machine.
sample of the engine oil. Refer to Special Publication,
PEHP6001, “How To Take A Good Oil Sample” for 1. Remove the drain plug and allow the oil to drain
more information about obtaining a sample of the into a suitable container.
engine oil.
2. Clean the drain plug and install the drain plug.
i02251691
Transfer Gear Oil - Change

SMCS Code: 3159-044-OC
NOTICE
Refer to Special Publication, NENG2500, “Caterpillar Illustration 214

g00740253
suitable to collect and contain fluids on Caterpillar 3. Remove bolts (2) and cover (3) from the machine.
products. This will allow access to the drain plug for the
transfer gear oil tank.
mandates. The drain plug is located underneath the machine
on the front left side.
4. Remove the drain plug and allow the oil to drain

into a suitable container.
5. Install the drain plug, cover (3), and bolts (2).
contact skin.
6. Raise the hood.
Operate the machine until the oil is warm and the oil is
well circulated. Park the machine on a level surface. Refer to Operation and Maintenance Manual,
Ensure that the parking brake is fully engaged. Lower “Hood Control”.
the dump body and shut off the engine.
SEBU7814-06 153
Maintenance Section
Transfer Gear Oil Filter - Replace
i01976318
Transfer Gear Oil Filter -

Replace
SMCS Code: 3159-510-FI

contact skin.
Illustration 215
g00702070 NOTICE
7. Oil filler cap (4) for the transfer gear oil tank is during performance of inspection, maintenance, test-
located on the left side of the engine compartment. ing, adjusting and repair of the product. Be prepared to
The oil level gauge is attached to the oil filler cap. collect the fluid with suitable containers before open-
8. Unscrew and then remove the oil filler cap. Add nent containing fluids.
the oil for the transfer gear.
Refer to Operation and Maintenance Manual, Tools and Shop Products Guide” for tools and supplies
“Capacities (Refill)” and refer to Operation and suitable to collect and contain fluids on Caterpillar
Maintenance Manual, “Lubricant Viscosities”. products.
9. Clean the oil level gauge and the oil filler cap. Dispose of all fluids according to local regulations and
Install the oil filler cap. mandates.
10. Start the engine. Operate the machine until the oil Park the machine on a level surface. Ensure that the
is at operating temperature. Inspect the transfer parking brake is fully engaged. Lower the dump body
gear case for leaks. and shut off the engine.
11. Remove the oil filler cap and check the oil level Drain the oil before removing the oil filter. Refer to
on the oil level gauge. Operation and Maintenance Manual, “Transfer Gear
Oil - Change” for information on draining the oil.
Note: Refer to Operation and Maintenance
Manual, “Transfer Gear Oil Level - Check” for more Note: Before you change the filter, block the front
information. frame of the machine.
12. Clean the oil level gauge and the oil filler cap.
13. Install the oil filler cap and tighten.
15. Clean up oil spills.
16. Lower the hood.

“Hood Control”.
g00742910
Illustration 216
The oil filter for the transfer gear is located on the rear of the tractor
on the right side of the rear frame.
1. Clean the outside of the oil filter for the transfer

gear.
154 SEBU7814-06
Maintenance Section
Transfer Gear Oil Level - Check
2. Remove the oil filter with a strap type wrench. 3. Wipe oil filler cap (1) and oil filler tube (2).
Discard the used oil filter properly.
Note: The oil level dipstick is integral with the oil filler
Refer to Operation and Maintenance Manual, “Oil cap for the transfer gear. Oil filler tube (2) for the
Filter - Inspect”. transfer gear is located on the left side of the engine
compartment.
3. Clean the oil filter base.
4. Turn the handle on the oil level dipstick in order to
4. Apply a thin coat of oil to the seal of the new oil remove the dipstick. Remove the oil level dipstick.
filter.
5. Clean the dipstick by wiping.
5. Install the new oil filter by hand. When the seal
contacts the oil filter base, turn the oil filter by 270° 6. Install the dipstick fully.
more. This will tighten the oil filter sufficiently.
7. Remove the dipstick.
i02231974
Transfer Gear Oil Level - Check

SMCS Code: 3159-535-FLV; 3159-535-OC
NOTICE
Refer to Special Publication, NENG2500, “Caterpillar Illustration 218

g00740112
suitable to collect and contain fluids on Caterpillar Note: The oil level dipstick is marked: “MIN COLD”
products. (3) , “MIN HOT” (4), and “MAX HOT” (5).
Dispose of all fluids according to local regulations and 8. Check the oil on the dipstick.
mandates.
Note: The engine can be started if the oil is above
Check the oil level before the engine is started. the mark “MIN COLD”(3).
1. Park the machine on a level surface. Engage the 9. If necessary, add oil through filler tube (2) until
parking brake and lower the dump body. the level is at the “MIN COLD” mark. Refer to
Operation and Maintenance Manual, “Lubricant
2. Raise the hood. Refer to Operation and Viscosities”.
the handle on the dipstick in order to make the
seal between the filler tube and the filler cap.
11. Lower the hood.

temperature of the oil is at normal operating
temperature.

parking brake. Shut off the engine.
14. Raise the hood. Remove oil level dipstick (1).

g01125860 15. Clean the dipstick by wiping.
Illustration 217
SEBU7814-06 155
Maintenance Section
Transfer Gear Oil Sample - Obtain
17. Remove the dipstick.
18. Check the oil level on the dipstick. If the oil is

between the range “MIN HOT” (4) and “MAX HOT”
(5) this is normal. Maintain the oil level within this
area on the dipstick. If necessary, add oil through
filler tube (2). Refer to Operation and Maintenance
Manual, “Lubricant Viscosities”.
the handle of the dipstick in order to make the seal
g00847341
20. Close the hood. Illustration 219
Location of the sampling valve for the transfer gear
i01980902 1. Operate the machine until the oil reaches

operating temperature.
Transfer Gear Oil Sample -
Obtain 2. Park the machine on a level surface. Lower the
dump body and engage the parking brake.
SMCS Code: 3159-008; 3159-554-OC
NOTICE
Care must be taken to ensure that fluids are contained 4. Install the steering frame lock. Refer to Operation
during performance of inspection, maintenance, test- and Maintenance Manual, “Steering Frame Lock”.
collect the fluid with suitable containers before open- Note: Before you obtain a sample of the oil, block the
ing any compartment or disassembling any compo- front frame of the machine.
5. Install the oil drain tube assembly to the sampling
Refer to Special Publication, NENG2500, “Caterpillar valve.
suitable to collect and contain fluids on Caterpillar 6. Start the engine.
products.
7. Drain an oil sample from the sampling valve.
mandates. 8. Shut off the engine.
9. Remove oil drain tube assembly from the sampling

valve.
Hot oil and hot components can cause personal Use S·O·S oil analysis in order to monitor the
injury. Do not allow hot oil or hot components to condition of the transfer gear.
contact skin.
i02232267
Wheel Nut Torque - Check

SMCS Code: 4210-535
Check the wheel nut torque on any new wheels and

on any repaired wheels until the specified wheel nut
torque is maintained. Check the wheel nut torque of
all six wheels at the normal maintenance interval
thereafter. Refer to Operation and Maintenance
Manual, “Maintenance Interval Schedule”.
156 SEBU7814-06
Maintenance Section
Window Washer Reservoir - Fill
4. Fill the reservoir through the filler opening.
5. Replace the filler cap of the reservoir and lower

the hood. Refer to Operation and Maintenance
Manual, “Hood Control”.
i01496481
Window Wiper -
Inspect/Replace
SMCS Code: 7305-040; 7305-510
g01125960
Illustration 220 parking brake. Lower the dump body and shut off
the engine.
Tighten the wheel nuts to a torque of 475 ± 60 N·m
(350 ± 44 lb ft).
i01401274
Window Washer Reservoir -

Fill
SMCS Code: 7306-544
NOTICE
When operating in freezing temperatures, use
Caterpillar or any commercially available nonfreezing
window washer solvent.
g00776803
Illustration 222
Inspect the front wiper blade. Inspect the rear wiper

blade, if equipped.
Replace a wiper blade when the following conditions

occur:
• The wiper blade is causing streaks on the front

window.
• The wiper blade is causing streaks on the rear

window.
• The wiper blade is worn.

g00738419
Illustration 221
• The wiper blade is damaged.
The window washer reservoir is located inside the
engine compartment on the left side. Note: Damaged wiper blades may cause permanent
damage to the glass of the cab windows.
Perform the following operations in order to access
and fill the window washer reservoir:

parking brake and shut off the engine.

3. Remove the filler cap of the reservoir.

SEBU7814-06 157
Maintenance Section
Windows - Clean
i01495125
Windows - Clean
SMCS Code: 7310-070
g00776437
Illustration 223
Use commercially available window cleaning

solutions and a clean cloth to clean the windows.
Clean the outside of the windows from the ground
unless handholds can be utilized from positions on
the deck.
Use a device with a long handle or steps in order to

clean the windows from the ground.

725 AND 730 Articulated Trucks: Maintenance Intervals

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SAFETY.CAT.

725 AND 730

Excerpted from Operation & Maintenance Manual (SEBU7814-06-01)

i02658699 Cooling System Coolant Level - Check ............... 111

Every 50 Service Hours Every 2000 Service Hours

Brake System Air - Purge ................................... 105

Every 3000 Service Hours

Every 3 Years After Date of Installation or

Every 4000 Service Hours

Every 5000 Service Hours

Every 6000 Service Hours

Note: If too much grease is pumped into the reservoir,

Note: Due to the slow capability of a hand held

• Check the conditions of the grease points that

• Check the operation of the system. Perform a

• Clean the lubrication pump and clean the

• Every 500 hours replace the filter or every 500

Note: The automatic lubrication system reduces

The use of a partially fluid grease that is above the

• Excessive component wear

Center axle breather (2) is mounted on the right side

Axle Breathers - Clean/Replace

Park the machine on a level surface. Move the

Install the Steering Frame Lock. Refer to Operation

Rear axle breather (3) is mounted on the right side of

Note: Before you remove the breathers, block the

1. Remove each axle breather.

Note: The engine is equipped with a belt tensioner

i01951790 2. Raise the hood. Refer to Operation and

8. Install belt (1) in the following order: tensioner (3),

i02207824 Personal injury or death can result from improper

Never use an adapter to connect your nitrogen

Refer to Systems Operation, Testing and Adjusting,

Brake Pads - Check

A tool can be manufactured in order to facilitate

Fabricate a tool from suitable black steel stock or

Note: The gauge needs to be used in both holes

Brake System Air - Purge

Routine purging of the service brake lines ensures

Brakes, Indicators and Gauges

Before you operate the machine, perform the

• Stop the engine.

Test the service brakes and the secondary steering

3. Gradually increase the engine speed until the NOTICE

4. If the machine moves at an engine speed below

i02206819 3. Remove cover (2) and remove the air filter.

To prevent decreased performance, clean the filter el-

Both cab air filters must be serviced at regular

If the air filter is damaged, replace the air filter.

7. Install the air filters. Use the arrows on the air

8. Install cover (2) and cover (1).

Circuit Breakers - Reset

The circuit breaker panel is located to the right of the

Circuit Breakers for the Alternator

Circuit breakers protect the electrical system from g00677639

The circuit breaker for the headlamp is located behind

Heater/Air Conditioner (1) – 15 amp

Hood Control Switch (6)

Personal injury can result from hot coolant, steam