Home

MAINTENANCE INTERVALS - Safety

1. Illustration 140 900104078 2 Set the air conditioner control for maximum cooling Set the fan speed switch knob to the HIGH position 3 To stabilize the air conditioning system run the air conditioning system for two minutes 4 Check for refrigerant in the system Feel the suction line and the discharge line If the system contains refrigerant the discharge line is warmer than the suction line 79 Maintenance Section Air Conditioner Test If the system does not contain refrigerant or the system contains only a small amount of refrigerant poor cooling will result 5 Stop the engine i01321387 Air Conditioner Belt Inspect Adjust Replace If equipped SMCS Code 1357 025 1357 040 1357 510 Inspect 1 Inspect the condition of the compressor drive belt The belt should deflect 14 to 20 mm 56 to 81 inch under 110 N 25 Ib of force Use a 144 0235 Belt Tension Gauge in order to measure the tension Adjust Replace 1 Loosen compressor mounting bolts 1 and 2 2 Loosen adjusting bracket nuts 3 3 To achieve the correct belt tension move the compressor inward or move the compressor outward Tighten adjusting bracket nuts 3 Tighten compressor mounting bolts 1 and 2 Recheck the belt adjustment 4 If necessary repeat Step 1 to Step Note Use the same procedure in order to replace the belt 80 Maintenance Section
2. 93 Equalizer Bar Pins Inspect 96 Ether Starting Aid Cylinder Replace 97 Front Idler Position Check 98 Fuel System Prime 100 FUSES Replace 104 Oil Filter 109 Radiator Core Clean 110 Radiator Pressure Cap Clean Replace 110 Ripper Tip and Shank Protector Inspect rien RE ENTRE TER ERE 111 Transmission Scavenge Screen Clean 120 Trunnion Bearing Adjust 121 Winch Wire Rope Install 126 Window Washer Reservoir Fill 126 Window Wipers Inspect Replace 127 Daily Fuel System 99 Every 10 Service Hours or Daily Backup Alarm 81 Brakes Indicators and Gauges Test 83 Cooling System Level Check 88 Engine Oil Level Check 94 Fuel Tank Water and Sediment Drain 103 Hydraulic System Oil Level Check 107 Seat Belt Inspect 112 Transmission Oil Level Check
3. 119 Walk Around Inspection 122 Winch Oil Level Check 125 Windows Clean 127 77 Maintenance Section Maintenance Interval Schedule Every 50 Service Hours or Weekly Pivot Shaft Oil Level Check 109 Ripper Linkage and Cylinder Bearings Lubricate gt eee 111 Track Pins 115 Initial 100 Service Hours Trunnion Bearing Adjust 121 Initial 250 Service Hours Engine Valve Lash Check 95 Transmission Oil Filter Replace 118 Every 250 Service Hours or Monthly Air Conditioner Test 79 Air Conditioner Belt Inspect Adjust Replace 79 Alternator and Fan Belts Inspect Adjust gi 80 Angle Blade Manual Tilt Brace Lubricate 81 Battery Inspect 82 Braking System 84 Bulldozer Lubricate 84 Cooling System Additive DEAC Add 85 Engine Oil Sample Obtain 94 Engine Oil and Filter Change 95 Equalizer Bar Pins Lubricate
4. 5 Install the filter element by hand When the seal contacts the base tighten the filter element for an additional 3 4 turn 6 Remove the retainer ring from the oil filler tube 7 Remove the strainer from the oil filler tube 8 Wash the screen in a clean nonflammable solvent 9 Inspect the seal on the filler cap Replace the seal if the seal is worn or if the seal is damaged 10 Install the strainer the retainer ring and the cap Illustration 202 900103770 11 Maintain the hydraulic oil to the FULL mark in the sight gauge Replace The Case Drain Filter 900103998 Illustration 203 1 Open the access door that is located between the hydraulic tank and the operators compartment 2 Remove the used filter element Discard the used filter element 3 Install the new filter element Turn the element until the element contacts the filter base Then tighten the element for an additional 3 8 to 1 2 turn 107 Maintenance Section Hydraulic System Oil Level Check 100072797 Hydraulic System Oil Level Check SMCS Code 5056 535 FLV 7479 At operating temperature the hydraulic tank is hot and under pressure Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand Relieve the filler cap slowly to relieve pressure The h
5. 7 Install all bolts and tighten the bolts to the specified torque Refer to Operation and Maintenance Manual Torques for Ground Engaging Tools 8 Raise the bulldozer blade and remove the blocking Lower the bulldozer blade to the ground 9 After you operate the machine for a few hours check all bolts for the proper torque 101096912 Differential and Final Drive Oil Sample Obtain SMCS Code 3258 008 4050 008 7542 008 A WARNING Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Obtain the sample of final drive oil as close as possible to the recommended sampling interval The recommended sampling interval is every 500 service hours In order to receive the full effect of 5 0 5 oil analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent oil samplin
6. 10 Amp Auxiliary Circuit 8 10 Amp Directional Control 9 10 Amp Flood Lights 10 10 Amp Brake System 11 10 Amp Horn 12 10 Amp Dump Valve 13 10 Amp 100751877 Hydraulic System Oil Change SMCS Code 5050 044 At operating temperature the hydraulic tank is hot and under pressure Hot oil and components can cause personal in jury Do notallow hot oil or components to contact skin Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand Remove the filler cap slowly in order to relieve pressure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates Operate the machine in order to warm the oil Park the machine on level ground Lower the bulldozer blade to the ground and apply slight downward pressure Lower the ripper if equipped to the ground Engage the parking brake and stop the engine 900103762 Illustration 197 105
7. 117 Transmission Oil Change 117 Winch Oil Change 124 Every 2000 Service Hours or 1 Year Air Conditioner System Check Replace 80 Engine Valve Lash Check 95 Engine Valve Rotators Inspect 96 Final Drive Oil Change 97 Hydraulic System Oil Change 105 Track Roller Frame Inspect 115 Track Roller Frame Guides Inspect 115 Every 3000 Service Hours or 2 Years Cooling System Coolant DEAC Change 86 Cooling System Extended Life Coolant Extender ron 87 Cooling System Water Temperature Regulator Clean Replace 89 Every 6000 Service Hours or 4 Years Cooling System Extended Life Coolant Change 87 Every 6000 Service Hours or 4 Years Cooling System Extended Life Coolant Change 87 100074075 Air Conditioner Test SMCS Code 7320 081 A WARNING Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Illustration 139 900104077 1 Start the engine Operate the engine at HIGH IDLE
8. 4 Remove oil filler cap 2 If necessary add oil 5 Clean the oil filler cap and install the oil filler cap 6 Close the access cover Engine Oil Sample Obtain SMCS Code 1000 008 7542 008 Hot oil and components can cause personal in jury Do notallow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates Obtain the sample of the engine oil as close as possible to the recommended sampling interval The recommended sampling interval is every 250 service hours In order to receive the full effect of 5 0 5 oil analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent oil samplings that are evenly spaced 1 Open the access cover on the left side of the machine 900318543 Illustration 172 The sampling valve for the engine oil is shown 2 Remove the protective cap 1 3 Use 8T 9190 Fluid Sampling Bottle Group 2 in order
9. Illustration 194 2 Open the drain valve Allow the water and the sediment to drain into a suitable container 3 Close the drain valve Close the access cover if equipped 104 Maintenance Section Fuses Replace 100753704 Fuses Replace SMCS Code 1417 510 900340187 Illustration 195 The fuse panel is located in the battery compartment on the left side of the machine system from damage that is caused by overloaded electrical circuits Replace a fuse if the element separates If the fuse of a particular electrical system requires frequent replacement check the electrical circuit Repair the electrical circuit if necessary Fuses Fuses protect the electrical NOTICE Always replace fuses with the same type and capacity fuse that was removed Otherwise electrical damage could result NOTICE If itis necessary to replace fuses frequently an elec trical problem may exist Contact your Caterpillar dealer CU do 5 aO Uu Illustration 196 900103744 D amp O 0 Cigar Lighter 1 10 Amp Electrical Power for Cab 2 10 Amp Key Start Switch 3 10 Amp Air Conditioner 4 20 Amp Electronic Clutch Brake 5 10 Amp Windshield Wiper Washer 6 15 Amp Caterpillar Monitoring System Panel 7
10. Move the sliding section of the window to opening 4 in the upper window channel Tilt the top of the window toward the inside of the cab Remove the window Stay inside the cab in order to clean the outside of the rear window After cleaning install the sliding section of the rear window
11. of the machine Turn the red handle of the fuel shutoff valve in order to shut off the fuel supply Open the access cover for the engine compartment The access cover is located on the right side of the machine 900103875 Remove the filter with strap wrench Wash the filter mounting base in clean nonflammable solvent Make sure that all of the old seal is removed Coat the seal of the new filter element with clean diesel fuel Install the new filter element by hand When the seal contacts the base tighten the filter element for an additional 3 4 turn Rotation index marks are positioned on the filter elements at 90 degree intervals Use these rotation index marks as a guide when you tighten the filter Open the fuel shutoff valve Close the access door if equipped 102 Maintenance Section Fuel System Secondary Filter Replace 8 Prime the fuel system 100073327 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE A WARNING 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 A WARNING Personal injury can result when using cleaner sol venis To help prevent personal injury follow the instruc tions and warnings on the cleaner s
12. 101279658 Window Washer Reservoir Fill SMCS Code 7306 544 NOTICE When operating in freezing temperatures use Caterpillar or any commercially available nonfreezing window washer solvent 900103795 Illustration 258 GN Window Washer The washer fluid bottle is on the left side of the operator s compartment Open the access cover Remove the fluid bottle cap in order to fill the washer fluid bottle i01279804 Window Wipers Inspect Replace SMCS Code 7305 040 7305 510 Illustration 259 900103881 Inspect these wiper blades the front the right the left and the rear Replace any wiper blades that are damaged or worn Replace any wiper blades that streak the window i01124791 Windows Clean SMCS Code 7310 070 7340 070 Use commercially available window cleaning solutions to clean the windows To clean the outside of the rear window from the inside of the cab remove the sliding section of the rear window Use the following procedure in order to remove the sliding section of the rear window Illustration 260 900039956 1 Lift latch 1 in order to slide the windows Squeeze latch 2 in order to move the window from the CLOSED position 127 Maintenance Section Window Wipers Inspect Replace Move handle stop 3 to the UP position To move the handle stop to the UP position lift the handle and rotate the handle simultaneously Rotate the handle until the handle is vertical
13. 199 900103764 15 Maintain the oil level to the FULL mark in the sight gauge Add oil if necessary 16 Stop the engine 100751928 Hydraulic System Oil Filter Replace SMCS Code 5068 510 At operating temperature the hydraulic tank is hot and under pressure Hot oil and components can cause personal in jury Do notallow hot oil or components to contact skin Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand Remove the filler cap slowly in order to relieve pressure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates Illustration 200 900103768 1 Slowly remove the hydraulic tank filler cap in order to relieve the system pressure 900103769 Illustration 201 2 Remove the retaining nut 3 Remove the cover and the filter assembly 4 Remove the filter element Properly discard the filer element Apply a thin coat of oil to the seal on the new filter
14. Code 1273 070 STR 1273 070 Z2 Illustration 192 900666728 The fuel cap is located on the rear of the machine The cap is on the left side of the machine Only vented fuel caps have filters Machines without the fast fill fuel arrangement require a vented fuel cap Illustration 193 900668917 1 Lift lever 3 in order to remove the fuel tank filler cap Turn the lever counterclockwise until the lever stops Lift the cap straight up in order to remove the cap 2 Remove the fuel strainer from the filler neck 3 In order to remove the filter assembly remove two screws that secure filter assembly 2 to the fuel cap Remove filter assembly 2 valve 1 and the gaskets 4 Wash the cap and the strainer in a clean nonflammable solvent 103 Maintenance Section Fuel Tank Cap Filter and Strainer Replace Clean 5 Inspect the tank cap seal If the seal is damaged replace the seal 6 Replace the filter assembly the valve the gaskets and the screws Use a 9X 2205 Cap Filter Kit 7 Install the strainer 8 Install the fuel cap Rotate the fuel cap clockwise until three tabs 5 drop into the slots in the adapter Rotate lever 3 clockwise until the lever stops Lower lever 3 over locking tab 4 100072950 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S The drain valve is under the fuel tank at the rear of the machine 1 Open the access cover if equipped 900103760
15. Tilt Blade SMCS Code 6050 086 900665856 Illustration 151 The Power Angle Tilt Blade is shown separately for photographic purposes Lubricate the Power Angle Tilt Blade at every 250 hour interval 1 Lubricate the bearings on the ends of each hydraulic cylinder 6 points 2 Lubricate the bearings on each end of the stabilizer link 2 points 3 Lubricate the trunnion bearing 1 point 100072752 Cab Air Filter Clean Replace SMCS Code 7342 070 Fl 7342 510 Fl Clean Filters Note Clean the filters more often in dusty conditions Illustration 152 900103708 1 Remove the filter cover and the filter elements The filter cover is in front of the cab 2 Remove the filter elements that are positioned in the operator s compartment Clean the filter elements with pressure air or wash the elements in warm water and in a nonsudsing household detergent 3 Rinse the filter elements in clean water and air dry the elements thoroughly 4 Install the filter elements Install the filter cover 100753322 Circuit Breakers Reset SMCS Code 1417 529 1420 529 900339673 Illustration 153 The fuse panel is in the battery compartment on the left side of the machine 85 Maintenance Section Circuit Breakers Reset nO m sO OOO 0 0000 Illustration 154 900103722 Circuit Breaker Reset Push in the button in order to reset
16. 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 Initially replace the transmission oil filter after 250 service hours Also replace the transmission oil filter after the initial 500 service hour interval Thereafter replace the transmission oil filter after every 500 service hours Replace the filter element if the transmission oil filter indicator comes on during operation The transmission oil filter is located behind the access cover on the right side of the machine Illustration 235 900104052 1 Remove the filter housing drain plug The filter housing drain plug is located under the fender on the right side of the machine Drain the oil into a suitable container Reinstall the filter housing drain plug Illustration 236 900103792 2 Remove the filter element cover 3 Remove the filter element and properly discard the filter element 4 Clean the filter element housing with a clean cloth 5 Inspect the seal If the seal is damaged replace the seal 6 Install the new filter element Install the filter element housing cover 7 Start the engine 900103793 Illustration 237 8 Maintain the oil level to the FULL mark on the dipstick If necessary add oil
17. in the thickness of the paint 8 Perform Steps 1 through 5 on the front bearing 9 Tighten the bolts that are on the front bearing to a torque of 430 60 N m 320 45 Ib ft 10 The assembly should move freely on the trunnion The specified minimum tolerance is 0 25 mm 0 010 inch Note Removal of one or more shims after a short period of time may be necessary Wear can be caused by normal variations of the surface or variations in the thickness of the paint 100073262 Walk Around Inspection SMCS Code 7000 040 NOTICE Accumulated grease and oil on a machine is a fire hazard Remove debris with steam cleaning or high pressure water at the specified interval in the Maintenance In terval Schedule or each time any significant quantity of oil is spilled on the machine Note Watch closely for leaks If leaking is observed find the source of the leak and correct the leak If leaking is suspected or leaking is observed check the fluid levels more frequently Illustration 244 990103813 e Inspect all of the implements for damage or for excessive wear Repair the implements if the implements are damaged Inspect the attachment cylinders and the attachment linkage for damage or for excessive wear Repair any damages Inspect the lights for broken bulbs and for broken lenses Replace any broken bulbs and any broken lenses Remove any trash buildup around the engine Remove any trash buildup that is under the f
18. low idle Watch the top surface of each valve rotator Whenever an inlet valve closes or an exhaust valve closes each valve rotator should turn If a valve rotator fails to turn consult your Caterpillar dealer for service 100072763 Equalizer Bar Pins Inspect SMCS Code 7206 040 PN 7207 040 PN Illustration 176 900103710 Check the equalizer bar pins for looseness and for unusual wear If unusual wear is evident see the Service Manual or consult your Caterpillar dealer for an inspection and for repair instructions 100753601 Equalizer Bar Pins Lubricate SMCS Code 7206 086 PN 7207 086 PN NOTICE Apply lubricant to the fittings with a hand operated grease gun only Use of pressure operated lubricating equipment damages the seals Illustration 177 90034007 Remote Fitting 900103719 Illustration 178 Lubricate the equalizer bar center pin through the remote fitting The remote fitting is located on the frame on the left side of the machine The fitting is located below the dipstick Illustration 179 900103720 There are two additional end fittings that are located at each end of the equalizer bar Lubricate the equalizer bar end pins through the two end fittings 100072788 Ether Starting Aid Cylinder Replace SMCS Code 1456 510 CD 900103728 Illustration 180 1 Open the left engine access door The ether starting aid is located on the le
19. order to remove the tank cap 3 Fill the fuel tank with fuel Inspect the Tank Cap and the Strainer 1 Remove the fuel strainer from the filler neck 2 Inspect the strainer If the strainer is damaged replace the strainer 3 If necessary clean the strainer in a clean nonflammable solvent 4 Install the strainer 5 f necessary clean the inside of the tank cap 6 Inspect the tank cap seal If the seal is damaged replace the seal 7 Inspect tank cap filter 2 for damage Replace tank cap filter 2 if the filter is damaged Refer to the Fuel Tank Cap Filter and Strainer Replace Clean procedure in the maintenance section of this manual 8 Install the tank cap Rotate the tank cap clockwise until three tabs 5 drop into the slots in the adapter Rotate lever 3 clockwise until the lever stops Lower lever 3 over locking tab 4 100072933 Fuel System Prime SMCS Code 1258 If the engine does not start air may be trapped in the fuel lines to the engine Use the following procedure in order to purge air from the fuel lines Fuel Priming Pump If Equipped The fuel priming pump is located in the engine compartment on the right side of the machine Illustration 188 900103758 1 Unlock the priming pump plunger Operate the plunger until you feel resistance 2 Push in the plunger Hand tighten the plunger 3 Start the engine If the engine does not start or if the engine continue
20. percent maximum Illustration 155 900102263 1 Slowly loosen the filler cap in order to relieve the pressure Remove the cap 2 Add supplemental coolant additive Drain some coolant from the radiator into a suitable container in order to allow space for the extra coolant additive Note Always discard drained fluids according to local regulations 3 Add 0 24 L 50 pint of supplemental coolant additive for every 38 L 10 US gal of engine cooling capacity 4 Inspect the filler cap gasket Replace the filler cap if the gasket is damaged 5 Install the filler cap i00760772 Cooling System Coolant DEAC Change SMCS Code 1352 044 1395 044 NOTICE Make sure you read and understand the information in the topics Safety and Cooling System Specifica tions for all information pertaining to water antifreeze and supplemental coolant additive requirements be fore you proceed with maintenance of the cooling sys tem NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids accor
21. the circuit breaker If the electrical system is working properly the button will remain depressed If the button does not remain depressed check the appropriate electrical circuit Repair the electrical circuit if necessary 1 Alternator 80 Amp 2 Heater and Air Blower Motor Reset 20 Amp 100072729 Cooling System Additive DEAC Add SMCS Code 1352 510 See the appropriate topics in your machine s Operation and Maintenance Manual for all cooling system requirements Use 8T 5296 Test Group to check the concentration of the coolant If necessary add supplemental coolant additive 86 Maintenance Section Cooling System Coolant DEAC Change NOTICE Do not exceed the recommended six percent sup plemental coolant additive concentration Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system reducing the engine s heat heat transfer characteristics Reduced heat transfer could cause cracking of the cylinder head and other high temperature components Excessive supplemental coolant additive concentration could also result in ra diator tube blockage overheating and or accelerated water pump seal wear Never use both liquid supple mental coolant additive and the spin on element if equipped at the same time The use of those addi tives together could result in supplemental coolant additive concentration exceeding the recommended Six
22. to obtain a sample 4 Replace the protective cap 5 Install the access cover Refer to Operation and Maintenance Manual Lubricant Viscosities for the correct fluid for your machine 100072867 Engine Oil and Filter Change SMCS Code 1308 1318 510 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin 1 Remove the crankcase drain access cover which is in the crankcase guard 2 Remove the crankcase drain plug Allow the oil to drain into a suitable container 900103750 Illustration 173 3 Remove the engine oil filter element and discard the engine oil filter element properly Make sure that all of the old filter seal is removed from the filter base 4 Apply a thin coat of oil to the new filter seals Install the new engine oil filter elements by hand When the gaskets contact the filter base tighten the filter elements by an additional turn of 270 degrees Rotation index marks are on the new filter elements These rotation index marks are spaced at 90 degree intervals Use these rotation index marks as a guide for proper tightening 95 Maintenance Section Engine Oil and Filter Change 5 Install the crankcase drain plug 900103751 Illustration 174 6 Remove the oil filler cap 1 Fill the crankcase with new oil See Operation and Maintenance Manual Refill Capacities Clean the oil filler cap and install the oil filler cap 7
23. used thermostat that has excessive buildup or deposits NOTICE Since Caterpillar engines incorporate a shunt design cooling system it is mandatory to always operate the engine with a thermostat Depending on load failure to operate with a thermo stat could result in either an overheating or an over cooling condition NOTICE If the thermostat is installed incorrectly it will cause the engine to overheat 4 Install a new seal in the thermostat housing Install a new thermostat and a new gasket Install the thermostat housing on the engine cylinder head 5 Install the elbow and the hose Tighten the hose clamp 100072674 Cutting Edges and End Bits Inspect Replace SMCS Code 6801 040 6801 510 6804 040 6804 510 n Illustration 160 900103694 1 Raise the bulldozer blade and block up the bulldozer blade When you remove the cutting edges and the end bits maintain the bulldozer blade at a minimum height 2 Remove the bolts Then remove the cutting edge and the end bits 3 Thoroughly clean all contact surfaces 90 Maintenance Section Differential and Final Drive Oil Sample Obtain 4 Inspect the opposite side of the cutting edge If the opposite side of the cutting edge is not worn turn the opposite side of the cutting edge outward and install the cutting edge 5 If both sides of the cutting edge are worn install a new cutting edge section 6 Repeat Step 4 and Step 5 for the end bits
24. 900103817 e Inspect the tracks Repair the tracks if the tracks are damaged or excessively worn Tighten any loose bolts Replace missing bolts Check the tracks for excessive dirt buildup Check the tightness of the track Refer to Operation and Maintenance Manual Tracks Adjustment Check e Inspect the guiding guards for the track Check for loose bolts or for missing bolts Check the track components for damage and for wear e Inspect the operator compartment for cleanliness Remove any trash buildup and any dirt buildup e Inspect the instrument panel Repair any broken gauges and any broken lights g00103818 Illustration 248 e Make sure that the horn the backup alarm the lights the guards and the shield are working properly 124 Maintenance Section Winch Filter and Magnetic Strainer Replace Clean Winch Filter and Magnetic Strainer Replace Clean SMCS Code 5163 070 Fl MGS 5163 510 Fl MGS A WARNING Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Illustration 249 900040007 1 Remove the cover and the gasket 900040006 Illustration 250 2 Remove the filter element housing with a wrench 3 Remove the filter element from the filter element housing 4 Clean the filter element housing with a clean cloth 5 If the seal is damaged replace the seal Lubricate the seals with clean oil 6 Install a new filter e
25. 96 Fan Drive Pulley and Idler Lubricate 97 Final Drive Oil Level 98 Track Adjustment Adjust 113 Track Adjustment Check 115 Initial 500 Service Hours Transmission Oil Filter Replace 118 Every 500 Service Hours Differential and Final Drive Oil Sample Obtain 90 Hydraulic System Oil Sample Obtain 108 Transmission Oil Sample Obtain 120 Every 500 Service Hours or 3 Months Engine Crankcase Breather Clean 93 Fuel System Primary Filter Clean Replace 101 Fuel System Secondary Filter Replace 102 Fuel Tank Cap Filter and Strainer Replace Clean 103 Hydraulic System Oil Filter Replace 106 Recoil Spring Compartment Oil Level Check 110 Transmission Oil Filter Replace 118 Winch Filter and Magnetic Strainer Replace Clean 124 Every 1000 Service Hours or 6 Months Lift Cylinder Yoke Bearings Lubricate 109 Rollover Protective Structure ROPS Inspect 112 Torque Converter Scavenge Screen Clean 112 78 Maintenance Section Maintenance Interval Schedule Transmission Magnetic Screen Clean
26. Air Conditioner System Check Replace 101363439 Air Conditioner System Check Replace SMCS Code 7320 510 7320 535 A WARNING Personal injury can result from contact with refrig erant This system is under pressure at all times engine running or not Heat should never be applied to a charged system Contact with refrigerant can cause frost bite Keep face and hands away to help prevent injury Protective goggles must always be worn when re frigerant lines are opened even if the gauges in dicate the system is empty of refrigerant Always use caution when a fitting is removed Slowly loosen the fitting If the system is still un der pressure release it slowly in a well ventilated area Personal injury or death can result from inhaling refrigerant through a lit cigarette Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Do not smoke when servicing air conditioners or wherever refrigerant gas may be present Before any checks of the air conditioning and heating system are made move the machine to a smooth horizontal surface Lower all implements to the ground Make sure the transmission is in neutral or park and that the parking brake is engaged Keep all other personnel either away from the machine or where they can be seen Before you do a perform
27. Always measure the oil level with dipstick 2 in order to ensure that the correct amount of oil was added 8 On the dipstick maintain the oil level between the ADD mark and FULL mark 100072748 Engine Valve Lash Check SMCS Code 1102 1209 535 In order to perform the procedure for the valve lash check and for the engine valve lash adjustment refer to the Service Manual SENR2380 3304B amp 3306B Diesel Engines Note Make sure that qualified service personnel check the injector fuel timing If an adjustment is necessary make sure that qualified service personnel adjust the injector fuel timing Special tools and training are required Note The correct fuel timing specification is shown on the Engine Information Plate Fuel timing specifications will be different with each engine application and with each power rating Consult your Caterpillar dealer for the complete adjustment procedure 96 Maintenance Section Engine Valve Rotators Inspect i01394331 Engine Valve Rotators Inspect SMCS Code 1109 040 Caterpillar recommends replacing valve rotators that are operating improperly An improperly operating valve rotator will shorten valve life because of accelerated wear on the valves Also metal particles from a damaged valve rotator could fall into the cylinder and damage to the piston head and to the cylinder head may result Illustration 175 900038585 Start the engine and run the engine at
28. Linkage and Cylinder Bearings Lubricate SMCS Code 6313 086 BD L4 Illustration 214 900103773 Lubricate eleven grease fittings 100925689 Ripper Tip Shank Protector Inspect Replace SMCS Code 6808 040 6808 510 6810 6812 040 6812 510 If equipped 111 Maintenance Section Ripper Linkage and Cylinder Bearings Lubricate Illustration 215 900550432 When the ripper tip is worn close to the shank replace the ripper tip When the shank protector is worn close to the shank replace the shank protector If the tip is too blunt the tip will not penetrate properly 1 Raise the ripper Place blocking under the ripper Lower the ripper onto the blocking The ripper should be high enough so that the ripper tip or the shank protector can be removed Do not place the ripper too high 2 If the ripper tip is worn drive out the pin Remove the tip and the shank pin retainer 3 Clean the shank pin retainer and the pin 4 Install the new tip and the retainer 5 Install the pin from the opposite side of the retainer 6 If the shank protector is worn drive out the pins Remove the shank protector 7 Clean the pin retainers and the pins 8 Install the new shank protector and the retainers 9 Install the pins from the opposite side of the retainer 10 Raise the ripper and remove the blocking 11 Lower the ripper to the ground 112 Maintenance Section Rollover Protective S
29. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved A e SEBU6887 06 AATERPILLAR rasis Operation ane Maintenance manual DGR Track Type Tractor 4FM1 Up Machine 8TM1 Up Machine 9BM1 Up Machine 3ZN1 Up Machine 5LN1 Up Machine 7KN1 Up Machine 9MN1 Up Machine 9PN1 Up Machine DMP1 Up Machine 4TR1 Up Machine 5PR1 Up Machine 5RR1 Up Machine 7DR1 Up Machine 7GR1 Up Machine 1RW1 Up Machine Differential Steering 101533183 Maintenance Interval Schedule SMCS Code 7000 Note All safety information warnings and instructions must be read and understood before you perform any operation or any maintenance procedure Before each consecutive interval is performed all of the maintenance requirements from the previous interval must also be performed When Required Battery Recycle 82 Battery Battery Cable or Battery Disconnect Switch Replace 82 Cab Air Filter Clean Replace 84 Circuit Breakers 85 Cutting Edges and End Bits Inspect Replace 89 Engine Air Filter Primary Element Clean Replace 90 Engine Air Filter Secondary Element Replace 92 Engine Air Precleaner Clean
30. Maintenance Section Hydraulic System Oil Change 1 Remove the hydraulic tank filler cap slowly in order to relieve any pressure 2 Wash the filler strainer and the filler cap in a clean nonflammable solvent 900103763 Illustration 198 3 Remove the oil drain plug The oil drain plug is located under the right rear of the machine 4 Attach a hose to a 1 inch NPT pipe nipple This 1 inch NPT pipe nipple should have a length of 100 mm 4 inch 5 Install the pipe nipple into the drain plug opening 6 Rotate the pipe nipple clockwise in order to open the internal drain valve Allow the oil to drain into a suitable container 7 Remove the pipe nipple The internal drain valve for the hydraulic tank will close 8 Clean the drain plug and install the drain plug Tighten the drain plug to a torque of 68 7 50 5 Ib ft 9 See Operation and Maintenance Manual Hydraulic System Oil Filter Replace Change the hydraulic system filter 10 Install the filler strainer 11 See Operation and Maintenance Manual Refill Capacities in order to determine the amount of hydraulic oil that is needed to fill the hydraulic oil tank Fill the hydraulic oil tank 12 Inspect the filler cap gasket Replace the gasket if damage or wear is evident 13 Install the filler cap 14 Start the engine Run the engine for a few minutes 106 Maintenance Section Hydraulic System Oil Filter Replace Illustration
31. NL 1395 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 proper service interval The amount of extender is determined by the cooling system capacity 88 Maintenance Section Cooling System Level Check Table 20 RECOMMENDED AMOUNT OF EXTENDER BY COOLING SYSTEM CAPACITY Recommended Amount of Extender 0 57 L 60 qt 0 71 L 75 qt 0 95 L 1 qt 1 18 L 1 25 qt Cooling System Capacity 22 to 30 L 6 to 8 US gal 30 to 38 L 8 to 10 US gal 38 to 491 10 to 13 US gal 49 to 64 L 13to 17 US gal Refer to Operation and Maintenance Manual Refill Capacities for the cooling system capacity For additional information about adding an extender see Operation and Maintenance Manual Coolant Recommendations or consult your Caterpillar dealer 100072607 Cooling System Level Check SMCS Code 1353 535 FLV 1395 535 FLV At operating temperature the engine coolant is hot and under pressure Steam can cause personal injury Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand Remove the fill cap slowly to relieve pressure Cooling system conditioner contains alkali Avoid contact with the skin and eyes to prevent personal injury This machine s radiat
32. Regulator Clean Replace 7 Inspect the radiator core for debris Clean the radiator core if necessary Use compressed air high pressure water or steam to remove dust and debris from the radiator core However the use of compressed air is preferred 101000516 Cooling System Water Temperature Regulator Clean Replace SMCS Code 1355 070 1355 510 1393 Replace the thermostat on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system A new thermostat should be installed after the cooling system has been cleaned Install the thermostat while the cooling system is completely drained or while the cooling system coolant is drained to a level that is below the thermostat housing NOTICE Failure to replace the engine s thermostat on a regu larly scheduled basis could cause severe engine dam age Note If you are only installing a new thermostat drain the cooling system coolant to a level that is below the thermostat housing 1 Loosen the hose clamp and remove the hose from the elbow Disconnect the hose assembly from the thermostat housing assembly 2 Remove the bolts from the elbow Remove the elbow and the thermostat housing assembly 3 Remove the gasket the thermostat and the seal from the thermostat housing NOTICE A used thermostat can be installed if the thermostat conforms to test specifications and the thermostat is not damaged Do not install a
33. ake necessary repairs or replace the battery 6 Connect the negative battery cable at the battery 7 Connect the battery cable at the battery disconnect switch 8 Install the key and turn the battery disconnect switch to the ON position 100074117 Brakes Indicators and Gauges Test SMCS Code 4100 081 7000 081 7450 081 Illustration 149 900104090 Check the operation of the Caterpillar Monitoring System Observe the self test when you start the engine The system performs an automatic self test when you turn the engine start switch to the ON position The self test verifies that the monitoring panel and the display modules are operating properly The internal circuits the indicators and the gauges are automatically checked Illustration 150 900104091 83 Maintenance Section Brakes Indicators and Gauges Test The operator must observe the indicators and the gauges in order to determine whether module 1 module 2 module 3 the indicators and the gauges are operating properly The self test lasts for approximately three seconds During the self test all alert indicators flash The digital display shows the following readouts e All indicators of units Deg C kPa miles km rpm and liters e X10 readout e Symbol for the hour meter e 8 8 8 X 8 8 readout The pointers in the gauges point upward Then the pointers p
34. ance check of the air conditioning system check the following items 1 Check the condenser a Check for any type of restriction that will obstruct the air flow Check for dirt insects plastic bags etc b With condensers that are mounted on the roof always check that both the fan motors are running Check for restrictions A clean condenser will lead to longer life for the compressor Illustration 141 900737294 2 Clean the fresh air filters 900737301 Illustration 142 3 Clean the recirculation filters 4 Replace the in line dryer annually Reference Refer to the topics of Service Manual SENR5664 Receiver Refrigerant Dryer Remove and Install and of Service Manual SENR5664 In Line Refrigerant Dryer Remove and Install in the Service Manual for your machine 100072461 Alternator and Fan Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 1 Open the access door on the right side of the machine Note Even if only one belt is worn or damaged replace the belts in sets Illustration 143 900103677 2 Inspect the condition of the fan and of the alternator belt The belts should deflect 9 to 15 mm 38 to 62 inch under 110 N 25 Ib of force 900103678 Illustration 144 3 Loosen the adjusting locknut 4 Turn the adjusting nut until the correct belt tension is reached To achieve the correct belt adjustment move the alternator inward or move the a
35. and cap 2 on trunnion assembly 3 without shims 3 Tighten the bolts that are on cap 2 to a torque of 50 N m 37 Ib ft Maintain equal distance on both space A and space B of cap 2 Observe spaces A and B in order to determine the required number of shims 4 Loosen the bolts that are on cap 2 As needed Illustration 242 900666217 insert shims into spaces and B When possible use an equal number of shims for Adjust the trunnion bearings after the initial 100 spaces A and B hours Note The number of shims at space A must be 1 Lower the bulldozer blade to the ground Walk within one of the number of shims at space B For to the left side of the machine example if space A has eight shims space B must have seven eight or nine shims 2 Remove two nuts 3 from two bolts 1 on the n trunnion bearing 5 Add one additional shim to space A Add one additional shim to space B 3 Remove two bolts 1 bearing cap 2 and two shim packs A and B as a unit 122 Maintenance Section Walk Around Inspection 6 Tighten the bolts that are on cap 2 to a torque of 1050 150 N m 775 110 Ib ft 7 The assembly should move freely on the trunnion The specified minimum tolerance is 0 25 mm 0 010 inch Note Removal of one or more shims after a short period of time may be necessary Wear can be caused by normal variations of the surface or variations
36. ccording to local regulations and mandates 98 Maintenance Section Final Drive Oil Level Check Illustration 182 1 900100627 Position one final drive so that oil level mark 1 is horizontal The drain plug 3 will point downward Remove drain plug 3 Allow the oil to drain into a suitable container Inspect the drain plug seal Replace the drain plug seal if the drain plug seal is damaged Clean the drain plug and install the drain plug Remove oil filler plug 2 Fill the final drive with oil to the bottom of the filler plug opening See Operation and Maintenance Manual Refill Capacities Inspect the condition of the seal of the filler plug Replace the plug seal if the plug seal is damaged Repeat Step 1 to Step 7 in order to change the oil in the other final drive i01023410 Final Drive Oil Level Check SMCS Code 4050 535 Fl V Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Illustration 183 1 900100625 Position one final drive so that oil level mark 1 is horizontal and drain plug 3 is at the bottom Remove oil filler plug 2 The oil level should be at the bottom of the filler plug opening Add oil if necessary See the Table in the article Lubricant Viscosities for the type of oil Install oil filler plug 2 Repeat Step 1 to Step 4 in order to check the oil le
37. der to equalize the pressure Allow the machine to coast to a complete stop Do not use the brakes Measure dimension 2 again Repeat Steps 4 and 5 until dimension 2 is correct Install the access cover Bolt Torque for Track Shoes The torque requirement for track shoe bolts is 400 70 N m 300 50 Ib ft Tighten the bolts by an additional turn of 120 degrees If you are using bolts with a master link tighten the bolts to a torque of 400 70 N m 300 x 50 Ib ft Then tighten the bolts by an additional turn of 180 degrees 100073031 Track Adjustment Check SMCS Code 4170 535 Illustration 224 900103790 Check the track adjustment Check the track for wear and for excessive dirt buildup If the track appears to be too tight or too loose see Operation and Maintenance Manual Track Adjustment Adjust i01123943 Track Pins Inspect SMCS Code 4175 040 PN Fingers can be burned from hot pins and bush ings The pins and bushings in a dry joint can become very hot It is possible to burn the fingers if there is more than brief contact with these components Use the recommendations in order to extend the life of the undercarriage Use the recommendations in order to avoid excessive downtime 1 During the machine operation listen for unusual squeaking and for unusual squealing This can indicate a dry joint 2 Check the machine for dry joints weekly Check for dry joints immediate
38. ding to local regulations and mandates Drain the coolant whenever the coolant is dirty or whenever foaming is observed The radiator cap is positioned in the top of the hood Illustration 156 900101147 1 Slowly loosen the radiator cap in order to relieve system pressure Remove the radiator cap 900103703 Illustration 157 2 The drain valve is under the radiator Open the drain valve Allow the coolant to drain into a suitable container 3 Close the drain valve Fill the system with a solution which consists of clean water and of cooling system cleaner The concentration of the cooling system cleaner should be 6 to 10 percent 4 Start the engine Run the engine for 90 minutes Stop the engine Drain the cleaning solution into a suitable container 5 While the engine is stopped flush the system with water Flush the system until the draining water is clear 6 Close the drain valve 7 Add the coolant solution See the following topics e Operation and Maintenance Manual Cooling System Specifications e Operation and Maintenance Manual Lubricant Viscosities e Operation and Maintenance Manual Refill Capacities Note If you are using Caterpillar antifreeze do not add the supplemental coolant additive at this time Also do not change the supplemental coolant additive element at this time 8 Start the engine Run the engine without the radiator cap until the thermostat opens and the co
39. e a grease pencil to make a mark on the tubular section of the front roller frame Make a mark on the rear of the roller frame This mark should correspond with the mark that is on the tubular section 900581643 Illustration 228 3 Raise the front of the machine with the hydraulics of the dozer Place the block under the inside edge of the same track grouser Lower the machine onto the block 900781106 Illustration 229 4 Put a mark on the tubular section of the front roller frame This mark should correspond with the mark on the rear roller frame Measure the distance between the two marks on the front roller frame If the distance between the two marks is greater than 4 5 mm 0 18 inch inspect the track roller frame guides for wear Repeat the entire procedure for the other side of the machine NOTICE Never build up the track roller frame guides with hard face welding This will cause serious wear damage to the guide slots in the front track roller frame E 1 Illustration 230 900781090 Track Roller Frame Guide If the dimension X is less than 45 3 mm 1 78 inch replace the track roller frame guides Reference Refer to Disassembly and Assembly Track Roller Frame Guides Remove and Install in the Service Manual for your machine or consult your Caterpillar dealer for information or for service i01146867 Transmission Magnetic Screen Clean SMCS Code 3030 070 MGS When you change
40. e torque converter 2 Disconnect the hose from the torque converter housing Illustration 218 900104059 3 Remove the screen from the torque converter housing 4 Wash the screen in a clean nonflammable solvent 5 Install the screen in the torque converter housing 6 Connect the hose to the torque converter housing 7 Install the bottom guard i01193190 Track Adjustment Adjust SMCS Code 4170 025 Procedure A WARNING Grease is under high pressure Grease coming out of the relief valve under pres sure can penetrate the body causing injury or death Do not watch the relief valve to see if grease is es caping Watch the track or track adjustment cylin der to see if the track is being loosened Loosen the relief valve only one turn Follow these steps in order to adjust the tension of the track 113 Maintenance Section Track Adjustment Adjust 1 Move the machine forward Allow the machine to stop without the use of the service brakes Adjust the tracks while you are in the machine s typical operating conditions If packing conditions prevail in the workplace adjust the tracks with packing material on the tracks 2 Make sure that the sag in the track is between the sprocket and the front idler Park the machine and shut off the engine 3 Establish a straight line from the grouser at the sprocket to the grouser at the front idler See Illustrati
41. embly in a clean nonflammable solvent 5 Shake the breather element until the breather element is dry You may also use pressure air to dry the breather element 6 Check the condition of the hose Replace the hose if the hose is damaged 7 Install the breather element cover assembly 8 Install the hose and the breather outlet hose clamps 9 Install the access cover 94 Maintenance Section Engine Oil Level Check 101365509 Engine Oil Level Check SMCS Code 1302 535 FLV 1326 535 FLV Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Do not under fill or overfill engine crankcase with oil Either condition can cause engine damage 1 The level gauge relies on gravity The machine must be on a level surface for an accurate check 2 Open the access cover that is on the left side of the machine 900103739 Illustration 171 3 Check the SAFE OPERATING RANGE side of the dipstick 1 while the engine is running and the oil is at operating temperature Maintain the oil level in the crosshatch on the dipstick Check the SAFE STARTING RANGE side of dipstick 1 while the engine is stopped The oil should be cold Maintain the oil level in the crosshatch on the dipstick Note When you operate the machine on severe slopes the oil level in the engine crankcase must be at the top end of the SAFE STARTING RANGE side of the dipstick
42. eplace 4 Clean the transmission magnetic screen See Operation and Maintenance Manual Transmission Magnetic Screen Clean 5 Open the engine access door for the transmission oil filler cap The engine access door is on the left side of the machine 118 Maintenance Section Transmission Oil Filter Replace 900103782 Illustration 233 6 Remove the transmission oil filler cap 7 Add oil To determine the correct amount of oil see Operation and Maintenance Manual Refill Capacities 8 Clean the transmission oil filler cap and install the transmission oil filler cap 9 Maintain the oil level to the FULL mark on the dipstick Illustration 234 900103784 10 Unscrew the transmission breather and remove the transmission breather The transmission breather is located on the top of the bevel gear case Remove the floorplate in order to access the transmission breather 11 Wash the transmission breather in a clean nonflammable solvent 12 Install the transmission breather i01193617 Transmission Oil Filter Replace SMCS Code 3067 510 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or
43. er Secondary Element Replace 9 Cover the clean filter elements Store the elements in a clean dry location A primary element may be cleaned for a maximum of six times Also replace the primary element if the primary element has been used for one year 10 Install a clean primary filter element 11 Clean the cover and install the cover 12 Close the access door if equipped 900103729 Illustration 166 13 Reset the filter element indicator Start the engine If the yellow piston in the filter element indicator moves into the red zone install a new primary filter element Also if the exhaust smoke is black install a new primary filter element 100072807 Engine Air Filter Secondary Element Replace SMCS Code 1051 510 SE 1054 510 SE NOTICE Always replace the secondary element Do not at tempt to reuse it by cleaning Engine damage could result Note Replace the secondary filter element when you service the primary element for the third time If a clean primary element has been installed and the filter element indicator still enters the red zone replace the secondary filter element Also if the exhaust smoke remains black and a clean primary filter element has been installed replace the secondary filter element 900103734 Illustration 167 1 Open the access cover if equipped 2 Remove the housing cover and the primary element Illustration 168 900039214 3 Remove the secondary eleme
44. ft front of the engine 2 Loosen the cylinder retaining clamp Unscrew the empty ether starting aid cylinder and remove the empty ether starting aid cylinder 3 Remove the used gasket Install the new gasket that is provided with each new ether starting aid cylinder 4 Install the new ether starting aid cylinder Tighten the ether starting aid cylinder by hand Tighten the cylinder retaining clamp securely 5 Close the engine access door 97 Maintenance Section Ether Starting Aid Cylinder Replace i01262397 Fan Drive Pulley and Idler Lubricate SMCS Code 1359 086 Illustration 181 900671267 Lubricate two fittings with Bearing Lubricant Special Purpose Grease SPG The fittings are for the fan drive pulley and for the idler belt tightener 100803315 Final Drive Oil Change SMCS Code 4050 535 FLV Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before Opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids a
45. g Bottle 1 to obtain a sample 4 After you take a sample remove the cap with the probe from the bottle Discard the cap with the probe Install the sealing cap that is provided with 8T 9190 Fluid Sampling Bottle 1 5 Replace the protective cap 6 Install the access cover Reference Refer to Lubricant Viscosities in the Maintenance Section of this manual for the correct fluid for your machine 100073242 Transmission Scavenge Screen Clean SMCS Code 3030 070 MGS When you change the transmission oil clean the scavenge screen 121 Maintenance Section Trunnion Bearing Adjust 4 Remove one shim from each shim pack A and fe 3 Install two bolts 1 bearing cap 2 and two shim packs A and B 6 Install two nuts 3 on two bolts 1 7 Tighten two nuts 3 to a torque of 1050 150 775 110 Ib ft 8 Repeat steps 2 through 7 on the right side of the machine 900104061 Procedure for Shimming Illustration 241 1 Remove the cover from the rear of the transmission The scavenge screen is located behind the cover 2 Wash the screen in a clean nonflammable solvent 3 Inspect the seal If the seal is damaged replace the seal 4 Install the screen and the cover 101499083 Bearing Adjust Illustration 243 Typical example 900292740 Ms Gode 605 025 1 Remove all of the shims from push arm assembly 1 2 Install assembly 1
46. gs that are evenly spaced If the machine is operated under a high load and or under high temperature conditions sample all fluids at the 250 hour interval Do not use the drain stream method to obtain a sample of the final drive oil A stream of dirty oil from the bottom of the compartment will contaminate the sample Likewise never dip an oil sample from an oil container or pour a sample from a used filter Two preferred methods are available for obtaining this sample e Use an in line sampling valve for pressurized oil systems e Use a sampling gun that is inserted into the sump Reference Refer to 5 5 Oil Analysis in the Maintenance Section of this manual for more information about these sampling methods Reference Refer to Lubricant Viscosities in the Maintenance Section of this manual for the correct fluid for your machine 100748057 Engine Air Filter Primary Element Clean Replace SMCS Code 1051 070 1051 510 PY 1054 070 PY 1054 510 PY Illustration 161 1 Open the access door if equipped The access door is located on the left side of the machine outside the operator s compartment Illustration 162 2 Remove the air cleaner cover Illustration 163 3 Remove the primary filter element from the air cleaner housing Illustration 164 4 Clean the inside of the air cleaner housing 900103726 900100510 Illustration 165 900039201 91 Maintenance Section Engi
47. history of data perform consistent oil samplings that are evenly spaced If the machine is operated under a high load and or under high temperature conditions sample all fluids at the 250 hour interval 1 Open the access cover on the right side of the cab Illustration 206 900103911 The hydraulic oil sampling valve is shown 2 Remove the protective cap 900318583 Illustration 207 3 Use 8T 9190 Fluid Sampling Bottle 1 to obtain the sample 4 After you take a sample remove the cap with the probe from the bottle Discard the cap with the probe Install the sealing cap that is provided with 8T 9190 Fluid Sampling Bottle 1 5 Replace the protective cap 6 Install the access cover Reference Refer to Lubricant Viscosities in the Maintenance Section of this manual for the correct fluid for your machine 100072423 Lift Cylinder Yoke Bearings Lubricate SMCS Code 5102 086 BD Illustration 208 900103662 The fittings are on the left front side of the machine and on the right front side of the machine Lubricate the bearings by applying grease to the fittings 100060978 Oil Filter Inspect SMCS Code 1318 507 3067 507 5068 507 Inspect A Used Filter for Debris Illustration 209 900100013 The element is shown with debris Use a 4C 5084 Filter Cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An exces
48. lement into the filter element housing 7 Tighten the filter element housing to a torque of27 4N m 20 3 Ib ft 8 Install the cover and the gasket Clean the Magnet and Clean the Strainer 900040008 Illustration 251 1 Remove the cover the magnet and the strainer 2 Clean these parts in a clean nonflammable solvent 3 Install the strainer and the magnet 4 Install the cover Winch Oil Change SMCS Code 5163 044 Hot oil and components can cause personal in jury Do notallow hot oil or components to contact skin 125 Maintenance Section Winch Oil Level Check 900039952 Illustration 252 Illustration 254 1 Remove the oil filler plug 8 Remove the breather on top of the winch case Wash the breather in a clean nonflammable solvent Install the breather 100038229 Winch Oil Level Check SMCS Code 5163 535 FLV Illustration 253 900039945 2 Remove the drain plug on the bottom of the winch Allow the oil to drain into a suitable container 3 Inspect the plug seal If necessary replace the plug seal Illustration 255 900039951 4 Clean the drain plug and install the drain plug When the engine is at low idle the oil should be 5 Fill the oil compartment until oil is visible in the visible in the sight gauge sight gauge See Operation and Maintenance Manual Refill Capacities 6 Clean the filler plug and install the filler plug 7 Run the engine a
49. less the job site requires a lower sound level 100998344 Battery Inspect SMCS Code 1401 040 Tighten the battery retainers on all batteries at every 1000 hour interval Perform the following procedures at every 1000 hour interval Check the following areas more often as required e Clean the top of the batteries with a clean cloth e Keep the terminals clean and coat the terminals with petroleum jelly e Keep the terminal covers in place 1 Open the battery access cover 2 Clean the top of the batteries with a clean cloth Keep the terminals clean and coated with petroleum jelly Install the terminal covers after you coat the terminals 3 Close the battery access cover 100058390 Battery Recycle SMCS Code 1401 561 Always recycle a battery Never discard a battery Always return used batteries to one of the following locations e A battery supplier e An authorized battery collection facility e Recycling facility 100760485 Battery Battery Cable or Battery Disconnect Switch Replace SMCS Code 1401 510 1402 510 1411 510 1 Turn the engine start switch key to the OFF position Turn all of the switches to the OFF position 2 Turn the battery disconnect switch to the OFF position Remove the key 3 Disconnect the battery cable at the battery disconnect switch The battery disconnect switch is connected to the machine frame 4 Disconnect the negative battery cable at the battery 5 M
50. loorplate Also remove any dirt buildup that is on the top of the crankcase guard Inspect the cooling system for leaks and repair any cooling system leaks Check the hoses the radiator fins the radiator cap and the drain area Inspect the engine precleaner screen for any dirt buildup and for debris buildup Remove any dirt and debris Inspect the engine compartment for leaks and repair any engine compartment leaks Check around all seals and around all covers Inspect the condition of the steps and of the handholds Inspect the steps and the handholds for cleanliness If necessary repair the steps or clean the steps Inspect the Rollover Protective Structure ROPS for damage Inspect the Falling Object Protective Structure FOPS for damage Consult your Caterpillar dealer for any necessary repairs 123 Maintenance Section Walk Around Inspection Illustration 245 900103815 e Inspect the hydraulic system for leaks Repair any hydraulic system leaks Inspect the hoses the seals and the flanges e Inspect the final drive for leaks Repair any final drive leaks 900103816 Illustration 246 e Make sure that the covers and the guards are secured Inspect the covers and the guards for damage for loose bolts and for missing bolts e Inspect the transmission for leaks Repair any transmission leaks Check around the seals and around the covers Also check the hoses around the transmission Illustration 247
51. lternator outward as required 5 Tighten the adjusting locknut 6 If new belts are installed check the belt adjustment again after 30 minutes of engine operation 7 Close the access door 81 Maintenance Section Angle Blade Manual Tilt Brace Lubricate 101034553 Angle Blade Manual Tilt Brace Lubricate SMCS Code 6074 086 If equipped Illustration 145 900103702 Lubricate the two fittings Use Multipurpose Lithium Complex Grease with Molybdenum MPGM i01309186 Backup Alarm Test SMCS Code 7406 081 Illustration 146 900103574 Turn the engine start switch to the ON position in order to perform the test 82 Maintenance Section Battery Inspect Illustration 147 900339521 Apply the service brakes Disengage parking brake switch 1 Move transmission direction selector 2 to the REVERSE position The backup alarm should sound immediately The backup alarm should continue to sound until the transmission direction selector is moved to the NEUTRAL position or to the FORWARD position 900637537 Illustration 148 The toggle switch is located under the protective cap The backup alarm is on the rear right side of the machine To adjust the sound level move the toggle switch that is on the rear of the backup alarm The backup alarm is set at the highest sound level when the machine is shipped from the factory The adjustment knob should remain at the HIGH position un
52. ly after machine operation After machine operation lightly touch the end of each track pin or bushing Touch the track pin or the track bushing with the back of your hand Make a mark on any dry track pin joint that is very hot to the touch 115 Maintenance Section Track Adjustment Check 3 Do not hit the ends of the track pins with a sledge hammer in order to loosen the track joints NOTICE Striking the end of a track pin introduces a significant amount of end play into the track joint and can result in early failures Consult your Caterpillar dealers Custom Track Service expert if you detect dry joints or leaks Your Caterpillar dealer s Custom Track Service expert can perform track inspection 100073058 Track Roller Frame Inspect SMCS Code 4151 040 900103791 Illustration 225 Inspect the track roller frame for leaks Check the seal for the pivot shaft for leaks Check the track rollers for leaks 101508708 Track Roller Frame Guides Inspect SMCS Code 4177 040 Measure the rotational movement of the front roller frame relative to the rear roller frame 116 Maintenance Section Track Roller Frame Guides Inspect Illustration 226 900581644 1 Raise the front of the machine with the hydraulics of the dozer Place a 100 mm 4 inch block under the outside edge of a track grouser Place the block near the track idler Lower the machine onto the block Illustration 227 900781096 2 Us
53. ne Air Filter Primary Element Clean Replace Inspect the primary element If the pleats the gaskets or the seals are damaged discard the element Replace a damaged primary element with a clean primary element NOTICE Do not clean the filter elements by bumping or tapping them Do not use filter elements with damaged pleats gaskets or seals Engine damage can result Make sure the cleaned filter elements are completely dry before installing into the filter housing Water re maining in the elements can cause false indications of contamination in Scheduled Oil Sampling test results 6 If the primary element is not damaged clean the primary element The filter elements can be cleaned by using the following methods Pressure air Pressure water e Detergent washing When you use pressure air the maximum air pressure is 205 kPa 30 psi When you use pressure water the maximum water pressure is 280 kPa 40 psi 900039203 7 When you clean the inside pleats and the outside pleats direct the air along the pleats or direct the water along the pleats The element can be washed in a solution that consists of warm water and of nonsudsing household detergent Fully rinse the pleats Allow the filter to air dry completely Inspect the filter elements after you clean the filer elements Do not use a filter if the pleats the gaskets or the seals are damaged 92 Maintenance Section Engine Air Filt
54. nt 4 Cover the air inlet opening Clean the inside of the air cleaner housing 5 Inspect the gasket between the air inlet and the housing If the gasket is damaged replace the gasket 6 Uncover the air inlet opening Install a new secondary element 7 Install the primary element and the air cleaner housing cover 8 Close the access cover if equipped 100072811 Engine Air Precleaner Clean SMCS Code 1050 070 900103735 Illustration 169 1 Inspect the air inlet screen for dirt and for trash 2 Remove the screen Clean the screen if the screen is dirty 3 Inspect the precleaner tube for dirt and for dust 4 Clean the precleaner tube with pressure air if the precleaner tube is dirty NOTICE Service the air cleaner only with the engine stopped Engine damage could result Run the engine at high idle If the yellow piston in the filter element indicator enters the red zone service the air cleaner Stop the engine 93 Maintenance Section Engine Air Precleaner Clean 100072815 Engine Crankcase Breather Clean SMCS Code 1317 070 Illustration 170 900103737 1 Loosen the breather outlet hose clamps Remove the hose from the breather cover 2 Loosen the breather inlet hose clamp Remove the engine crankcase breather 3 Check the condition of the cover seal Replace the cover seal if the cover seal is damaged 4 Wash the breather element and the breather element cover ass
55. oint to the left Then the pointers point to the right Then the pointers point to the final positions e The gear direction readout shows e The action light stays illuminated e he action alarm sounds once The monitoring panel is then in the normal operating mode If the above tests are not correctly completed the system will not function in the normal operating mode Consult your Caterpillar dealer for an electrical system check Any repairs must be made before you start the engine Turn on all of the machine lights Check for proper operation Sound the forward horn Move the machine forward and test the service brakes See Operation and Maintenance Manual Braking System Test Stop the engine Make any necessary repairs before you operate the machine 84 Maintenance Section Braking System Test 100074166 Braking System Test SMCS Code 4100 081 4267 081 A WARNING If the machine moves during the test reduce the engine speed immediately and engage the park ing brake If the machine moved while testing the brakes consult your Caterpillar dealer for brake inspec tion and repair Damaged brakes must be repaired before returning the machine to operation Make sure that the area around the machine is clear of personnel and clear of obstacles Test the brakes on a dry level surface Fasten the seat belt before you test the brakes The following test is used to determine whether
56. olant level stabilizes 9 Maintain the coolant level within 13 mm 5 inches of the bottom of the filler pipe 87 Maintenance Section Cooling System Extended Life Coolant Change 10 If the gasket is damaged replace the radiator cap Install the radiator cap 11 Stop the engine 100060003 Cooling System Extended Life Coolant Change SMCS Code 1350 044 1395 044 For information about adding an extender to your cooling system see Operation and Maintenance Manual Cooling System Extended Life Coolant Extender Add or consult your Caterpillar dealer Flushing the ELC from the Cooling System Some engines utilize Extended Life Coolant ELC See the Operation and Maintenance Manual Maintenance Interval Schedule for the proper service interval If an ELC was previously used flush the cooling system with clean water No other cleaning agents are required Flushing a Standard Coolant from the Cooling System If you change to an ELC from another type of coolant use a Caterpillar cleaning agent to flush the cooling system After you drain the cooling system thoroughly flush the cooling system with clean water All of the cleaning agent must be removed from the cooling system Note See the Operation and Maintenance Manual Cooling System Coolant Change for the draining procedure and for the flushing procedure 100743002 Cooling System Extended Life Coolant Extender Add SMCS Code 1350 1352 544
57. olvent contain er before using A WARNING Personal injury or death can result from a fire Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts g00103879 Illustration 191 Before you replace the secondary fuel filter element replace the primary fuel filter element The secondary fuel filter is behind the access door on the right side of the machine 1 Shut off the fuel supply The fuel shutoff valve is under the fuel tank on the rear of the machine 2 Remove the filter element Discard the filter element properly 3 Clean the filter housing base Make sure that all of the old seal is removed 4 Coat the seal of the new filter element with clean diesel fuel 5 Install the new filter element by hand When the seal contacts the base tighten the filter element for an additional 3 4 turn Rotation index marks are positioned on the filter element at 90 degree intervals Use these rotation index marks as a guide when you tighten the filter 6 Open the fuel shutoff valve 7 Prime the fuel system 101256077 Fuel Tank Cap Filter and Strainer Replace Clean SMCS
58. on 219 Illustration 219 900040329 4 If a machine does not have track carrier rollers the sag in the track is measured between the sprocket and front idler 2 The correct adjustment of dimension 2 is 115 10 mm 4 5 0 4 inch Illustration 220 900104000 5 If the machine is equipped with track carrier rollers calculate the average of dimension 3 and dimension 4 The correct average value is 55 10 mm 2 2 0 4 inch 114 Maintenance Section Track Adjustment Adjust Loose Track Adjustment Tight Track Adjustment Illustration 221 900040335 NOTICE Do not attempt to tighten track when dimension 1 is 150 mm 5 9 inch or more Contact your Caterpillar dealer for track service or in structions 1 Remove the access cover 900104001 Illustration 222 2 Add multipurpose grease MPGM through track adjustment valve 5 Add the MPGM until dimension 2 is correct 3 Operate the machine back and forth in order to equalize the pressure Allow the machine to coast to a complete stop Do not use the brakes 4 Measure dimension 2 again 5 Install the access cover Illustration 223 1 2 T 900104002 Remove the access cover Loosen relief valve 6 by one turn of 360 degrees Allow the grease to escape Close the relief valve Add MPGM through track adjustment valve 5 Add grease until dimension 2 is correct Operate the machine back and forth in or
59. or has a surge tank There is no top tank in this cooling system The surge tank has a filler cap and a sight glass It is not necessary to remove the filler cap in order to check the coolant level The sight glass is inside the engine compartment that is on the front left side of the machine The filler cap is beneath the access door that is on the top left side of the radiator guard Fee bt 949 Sel E Pe Illustration 158 1 Illustration 159 2 I 900103926 Observe the sight glass in order to verify the level of the coolant If the coolant completely covers the sight glass the coolant level is okay If the coolant level is visible in the sight glass the coolant is low 900101147 If it is necessary to add coolant remove the radiator cap slowly in order to relieve the pressure Fill the cooling system to the bottom of the filler tube Adding coolant above the bottom of the filler tube will cause the coolant to overflow the cooling system Maintain the coolant level between the top of the sight glass and the bottom of the filler tube If you need to add coolant daily check the cooling system for leaks 5 Inspect the radiator cap and the radiator cap seal for debris for foreign material or for damage Clean the radiator cap with a clean cloth Replace the radiator cap if the radiator cap is damaged Install the radiator cap 89 Maintenance Section Cooling System Water Temperature
60. s to misfire or smoke additional priming is necessary 4 Run the engine at the LOW IDLE position until the engine runs smoothly 100075818 Fuel System Primary Filter Clean Replace SMCS Code 1260 070 PY 1260 510 PY 1261 A WARNING 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 Personal injury or death can result from engine overspeed If the engine overspeeds it can cause injury or parts damage Be prepared to stop the engine by closing the air off to the air inlets or by manually pushing down ward on the governor shutdown rod A WARNING Personal injury or death can result from a fire Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters NOTICE Do not fill fuel filter with fuel before installing the fuel filter Contaminated fuel causes accelerated wear to fuel system parts Illustration 189 1 Illustration 190 3 4 101 Maintenance Section Fuel System Primary Filter Clean Replace 900103874 Open the access door if equipped at the rear
61. sion Oil Sample Obtain SMCS Code 3030 008 7542 008 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Obtain the sample of the transmission oil as close as possible to the recommended sampling interval The recommended sampling interval is every 500 service hours In order to receive the full effect of 5 5 oil analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent oil samplings that are evenly spaced If the machine is operated under high load and or under high temperature conditions sample all fluids at the 250 hour interval 1 Open the access cover on the right side of the cab Illustration 239 900318943 The oil sampling valve for the power train is shown 2 Remove the protective cap 900318825 Illustration 240 3 Use 8T 9190 Fluid Samplin
62. sive amount of debris in the filter element can indicate a possible failure 109 Maintenance Section Lift Cylinder Yoke Bearings Lubricate If metals are found in the filter element a magnet can be used to differentiate between ferrous metals and nonferrous metals Ferrous metals can indicate wear on steel parts and on cast iron parts Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings rod bearings or turbocharger bearings Small amounts of debris may be found in the filter element This could be caused by friction and by normal wear Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings to the crankshaft and to other parts This can result in larger particles in unfiltered oil The particles could enter the lubricating system and the particles could cause damage 100072817 Pivot Shaft Oil Level Check SMCS Code 4153 535 FLV Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Illustration 210 g00103736 The oil plugs are located on both sides of the machine on top of the track roller frame 110 Maintenance Section Radiator Core Clean Remove the plug on one side of the machine Check the oil level The oil level should be a
63. t low idle Maintain the oil level so that the oil level is visible in the sight gauge Illustration 256 900039947 126 Maintenance Section Winch Wire Rope Install Remove the oil filler plug If necessary add oil through the oil filler cap Check for oil leaks around the covers and around the hoses Repair any oil leaks 100052230 Winch Wire Rope Install SMCS Code 5163 012 Personal injury or death can result from worn wire rope cable Worn or frayed cable could break causing injury Check the wire rope cable If cable is worn or is frayed install a new cable The wire rope cable is attached to the drum that is on the winch The wire rope cable is attached with a standard cable ferrule The ferrule fits into a socket on the drum The wire rope cable is secured with a bolt down clamp Ferrules are made in several diameters and in several lengths Use the following table to specify the correct ferrule when you order a ferrule Table 21 DIAMETER CABLE FERRULES OF THE WIRE ROPE NUMBER OUTSIDE LENGTH CABLE DIAMETER 28 mm J9 60 0 mm 69 0 mm 1 125 inch 2 375 inch 2 750 inch 32 mm J8 60 0 mm 69 0 mm 1 250 inch 2 375 inch 2 750 inch Illustration 257 900039959 1 Put the wire rope cable in a straight line behind the machine 2 Remove clamp 1 and install the ferrule end into socket 2 3 Install clamp 1 4 Reel in the wire rope cable
64. t the bottom of the threaded hole If necessary add oil in order to bring the oil level up to the bottom of the threaded hole Repeat the procedure on the other side of the machine 100058126 Radiator Core Clean SMCS Code 1353 070 1805 1810 Cre ZZ lt 222 Ed 900100624 Illustration 211 You can use compressed air high pressure water or steam to remove dust and other debris from the radiator core However the use of compressed air is preferred See Special Publication SEBD0518 Know Your Cooling System for the complete procedure for cleaning the radiator core 100058123 Radiator Pressure Cap Clean Replace SMCS Code 1353 070 Z2 1353 510 42 Illustration 212 900100622 1 Slowly remove the radiator cap in order to relieve system pressure 2 Inspect the radiator cap for damage for deposits or for foreign material Clean the radiator cap with a clean cloth Replace the radiator cap if the radiator cap is damaged 3 Install the radiator cap 100072383 Recoil Spring Compartment Oil Level Check SMCS Code 4158 535 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin 1 Remove the cover plate for the oil filler Illustration 213 900100922 2 Maintain the oil level to the level mark on the dipstick 3 Install the cover plate 4 Repeat the procedure for the other recoil compartment 100072976 Ripper
65. that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 99 Maintenance Section Fuel System Fill Illustration 185 The fuel tank is located at the rear of the machine The tank cap for the fuel tank is located on the left side of the fuel tank See Operation and Maintenance Manual Refill Capacities Mounting and Dismounting the Machine 900666730 Illustration 186 The following route is the correct path to the tank Cap e Grasp the handhold on the fender e Step on the push arm e Step on the track shoes e Walk over the fender e Stand on the nonskid surface on the battery box e Hold the handhold on the ROPS support assembly with the left hand Fill the Fuel Tank 1 Clean the outside of the tank cap and the outside of the fuel tank filler neck 100 Maintenance Section Fuel System Prime Illustration 187 900668917 2 Lift lever 3 in order to remove the tank cap Turn the lever counterclockwise until the lever stops Lift the tank cap straight up in
66. the service brake is functional This test is not intended to determine the maximum brake holding effort The brake holding effort of this machine will be different than the brake holding effort of other machines because of variations in the engine setting in the power train efficiency and in the brake holding ability Compare the engine speed at the beginning of machine movement to the engine speed of a prior test This will be an indication of the amount of system deterioration 1 Start the engine Raise all implements Depress the brake pedal A N Select the mode of manual shift Release the parking brake 6 While the brake pedal is depressed move the directional control to the NEUTRAL position 7 Select the THIRD SPEED position The control panel will indicate 3N 8 Select the FORWARD position The control panel will indicate 9 Gradually increase the engine speed to full load speed The machine should not move 10 Move the directional control to the NEUTRAL position 11 Move the governor control lever to LOW IDLE Engage the parking brake Lower all implements to the ground Apply a slight down pressure Stop the engine NOTICE If the machine moved while testing the brakes contact your Caterpillar dealer Have the dealer inspect and if necessary repair the service brake before returning the machine to operation 101248965 Bulldozer Lubricate Power Angle
67. the transmission oil clean the magnet assembly and the screen 900103746 Illustration 231 1 Remove the bottom guard for access to the screen group 2 Remove the nuts which hold the cover to the housing 3 Remove the screen and the magnet assembly from the housing 4 Wash the screen and the magnet assembly in a clean nonflammable solvent 5 Inspect the seal If the seal is damaged install a new seal 6 Install the screen and the magnet assembly 7 Install the cover on the screen housing 8 Install the bottom guard 117 Maintenance Section Transmission Magnetic Screen Clean 100073011 Transmission Oil Change SMCS Code 3030 3080 044 A WARNING Hot oil and components can cause personal in jury Do notallow hot oil or components to contact skin Operate the engine in order to warm the oil Park the machine on level ground Lower all implements to the ground Apply slight downward pressure Engage the parking brake switch Stop the engine Some machines may be equipped with ecology drain valves 900103783 Illustration 232 1 Remove the transmission oil drain plug Drain the oil into a suitable container 2 Clean the transmission oil drain plug and install the transmission oil drain plug 3 Change the filter element See Operation and Maintenance Manual Transmission Oil Filter R
68. through the filler tube 9 Stop the engine 119 Maintenance Section Transmission Oil Level Check i01174960 Transmission Oil Level Check SMCS Code 3030 535 FLV 3080 535 FLV Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin The transmission oil dipstick is behind the engine access cover on the left fender of the machine g00103780 Illustration 238 1 Open the engine access cover Check dipstick 1 while the engine is operating at low idle and while the oil is at operating temperature Maintain the oil between the ADD mark and the FULL mark Note When you are operating the machine on severe slopes the quantity of oil in the transmission can be increased up to 10 percent When you are operating with the increased oil quantity prolonged operation in some machines can cause high transmission oil temperatures After the work on the severe slopes has been completed drain the excessive oil quantity from the bevel gear case 2 Remove filler cap 2 If necessary add oil 3 Clean the filler cap Install the filler cap Replace the filter element if the transmission oil filter indicator comes on during operation Reference Refer to Operation and Maintenance Manual Transmission Oil Filter Replace in this manual 4 Close the engine access cover 120 Maintenance Section Transmission Oil Sample Obtain i01216235 Transmis
69. tructure ROPS Inspect Rollover Protective Structure ROPS Inspect SMCS Code 7325 040 900103787 Illustration 216 Inspect the Rollover Protective Structure ROPS for bolts that are loose or damaged Replace any damaged bolts and any missing bolts with original replacement parts only Tighten the bolts to a torque of 900 100 N m 660 x 75 Ib ft Note Apply oil to all bolt threads for the ROPS before you install the bolts Improper bolt torque can result if you do not apply oil to the threads Do not weld reinforcement plates to the ROPS in order to straighten the ROPS Do not weld reinforcement plates to the ROPS in order to repair the ROPS If the ROPS has any cracks in the welds in the castings or in any metal section consult your Caterpillar dealer for repairs 100038410 SMCS Code 7327 040 900040782 Illustration 217 Always check the condition of the seat belt and the condition of the belt mounting hardware before you operate the machine Inspect the belt mounting hardware Replace any belt mounting hardware that is damaged or worn Regardless of the appearance replace the seat belt once during every three year interval 100073972 Torque Converter Scavenge Screen Clean SMCS Code 3101 070 MGS 3105 When you change the transmission oil clean the torque converter scavenge screen 1 Remove the bottom guard in order to gain access to th
70. vel in the other final drive i01256760 Front Idler Position Check SMCS Code 4159 Illustration 184 900669323 Adjusting shims B Dimension between the height of the front idler tread and the height of the roller tread The height of the front idler tread should always be higher than the height of the roller tread The dimension B is set approximately to 9 0 mm 35 inch at the factory Dimension B decreases as the undercarriage wears If a rebuilt idler or a new idler is installed with track rollers that are worn dimension B decreases Adjustment of the front idler to the correct height can improve the ride of the tractor and the performance of the dozer Use the following procedures to determine the best operating position If the machine is operated on FIRM UNDERFOOT conditions and excess vibration occurs shims can be removed in order to raise the front idler If the machine is operated on SOFT UNDERFOOT conditions and dozing performance is poor shims can be installed in order to lower the front idler Lowering the front idler can improve dozing performance If ground rippling by the dozer or excess vibration occur in soft material shims can be removed in order to raise the front idler Consult your Caterpillar dealer for detailed information about checking the idler and about adjustments to the idler i01250960 Fuel System Fill SMCS Code 1250 544 NOTICE Care must be taken to ensure
71. ydraulic tank is on the right rear side of the machine Illustration 204 900103732 1 Maintain the oil level to the FULL mark in the sight gauge 900103733 Illustration 205 108 Maintenance Section Hydraulic System Oil Sample Obtain 2 If the hydraulic system requires additional hydraulic oil remove the filler cap and add oil through the filler tube 3 Clean the filler cap and install the filler cap i01216225 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 7542 008 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Obtain the hydraulic oil sample as close as possible to the recommended sampling interval The recommended sampling interval is every 500 service hours In order to receive the full effect of 5 5 oil analysis you must establish a consistent trend of data In order to establish a pertinent

MAINTENANCE INTERVALS - Safety

Contents

Download Pdf Manuals

Related Search

Related Contents