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MAINTENANCE INTERVALS - Safety

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1. Illustration 274 g01018359 A Open fuse box B Open fuse panel Fuse listing ROPS floodlights 1 15 Amp Ripper floodlights 2 15 Amp ECM engine monitoring 3 Power train ECM 15 Amp Rear ROPS floodlights 4 15 Amp Auxiliary 5 10 Amp Spare 1 6 20 Amp GPS Radio Transmission Antenna 7 15 Amp Seat Ripper or Implements 8 15 Amp Standard Converter 9 10 Amp Spare 2 10 15 Amp AccuGrade 11 15 Amp Wipers 12 15 Amp Ignition Key 13 10 Amp Fender Floodlights 14 15 Amp Horn 15 15 Amp CAES Display 16 10 Amp Secondary Brake 17 10 Amp Unswitched Auxiliary 18 15 Amp Product Link 19 10 Amp Advisor Panel 20 15 Amp Implement ECM 21 15 Amp Implement ECM 22 15 Amp Engine ECM 23 20 Amp 24 VA 12 VA Converter 24 Attachment 20 Amp Cover 25 Fuse panel Fuse 26 175 Amp Fuse cover 27 Plastic Power outlet 28 12 Volt Starting Charging Analyzer 29 Plug 70 pin Connector HVAC blower 30 Reset button 15 Amp Fuse Puller 31 Auto Stop 102245859 High Intensity Discharge Lamp HID Replace If Equipped SMCS Code 1434 510 HID lamps operate at very high voltages To avoid electrical shock and personal injury disconnect power before servicing HID lamps HID bulbs become very hot during
2. Illustration 259 g00940433 9 Outer packing 10 Joint in the outer packing A Diameter A B 180 degrees 4 Install the outer packing 9 Offset the joint in the inner packing 8 and the outer packing 10 at 180 degrees Stretch the packing during installation Smooth the packing and keep the packing uniform Minimize the joint 10 at the ends of the outer packing 9 Illustration 260 g00939660 4 Bolt 5 Washer 6 Retainer 9 Outer packing 10 Joint in outer packing 11 Joint in retainers C 90 Degrees from joint in outer packing to joint in retainers Note The joint 10 in the outer packing 9 must be offset 90 degrees C to the joints 11 in the retainers 6 5 Assemble retainers 6 to seal guard 3 with washers 4 and bolts 5 The clearance at area D should be 2 mm 0 079 inch 6 Repeat steps 3 through 5 in order to replace the packing on the other final drive if necessary 102877617 Front Idler Position Check SMCS Code 4159 SystemOne Undercarriage The following check is for Caterpillar SystemOne Undercarriages that have the center tread idler SEBU7 763 03 167 Maintenance Section Front Idler Position Check r A Qo Og Q mE podpo godoodp ran go Le Illustration 261 g9 Iee
3. 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 S O S 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 Before you obtain an oil sample operate the machine until the oil is warm and the oil is well circulated 2 Open the engine access door if equipped on the left side of the machine Illustration 237 g01760274 3 Remove the protective cap 4 Obtain a sample of the engine oil from the engine oil sampling valve The sampling valve is located in the engine compartment on the left side of the machine Refer to Special Publication SEBU6250 S O S Oil Analysis for information that pertains to obtaining a sample of the engine oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the engine oil Note In order to obtain an oil sample from the engine compartment it may be necessary to increase the engine s speed Normally the oil sample is taken at low idle If the flow rate is too low increase engine speed to high idle in order to obtain the oil sample 5 Replace the protective cap 6 Close the engine acc
4. If a machine does not have carrier rollers the sag in the track is measured between the sprocket and the front idler The correct adjustment of dimension A for conventional undercarriage is 115 10 mm 4 5 4 inch See the following tables for information on the SystemOne Undercarriage if equipped Table 23 Track Sag No Carrier Minimum Target Maximum Roller Conventional 105 mm 115 mm 125 mm 4 1 inch 4 5 inch 4 9 inch SystemOne 80 mm 110 mm 120 mm 3 15 inch 4 30 inch 4 72 inch 1 Machines with the SystemOne undercarriage have tighter dimensions for track sag ae Illustration 328 g01118207 If the machine is equipped with a carrier roller calculate the average of dimension B and dimension C The correct average value is 65 10 mm 2 6 0 4 inch for the conventional undercarriage Table 24 Track Sag Carrier Minimum Target Maximum Roller Conventional 55 mm 65 mm 75 mm 2 2 inch 2 6 inch 3 0 inch SystemOne 45 mm 60 mm 70 mm 1 80 inch 2 40 inch 2 8 inch SEBU7763 03 197 Maintenance Section Track Pins Inspect Loose Track Adjustment ih g01019107 Illustration 329 NOTICE Do not attempt to tighten track when dimension D is 152 mm 6 0 inch or more The hard bottom attachment can be tightened to the point were D is no more than 152 mm 6 0 inch Cont
5. Dispose of all fluids according to local regulations and mandates Q Q Q 9 A g01113920 Illustration 272 The drain valve is under the fuel tank at the rear of the machine 1 Open the drain valve with the yellow handle Allow the water and the sediment to drain into a suitable container 2 Close the drain valve 102606338 Fuses and Circuit Breakers Replace Reset SMCS Code 1417 510 1420 529 1420 Fuses Fuses protect the electrical system from damage that is caused by overloaded electrical circuits Replace a fuse if the element separates If the fuse of a particular electrical system requires frequent replacement check the electrical circuit Repair the electrical circuit if necessary NOTICE Always replace fuses with the same type and capacity fuse that was removed Otherwise electrical damage could result NOTICE If it is necessary to replace fuses frequently an elec trical problem may exist Contact your Caterpillar dealer j 2 Illustration 273 g01118158 Open the cover for access to the circuit breakers and the fuses This is inside the operator station below the left armrest above the floorplate 174 Maintenance Section High Intensity Discharge Lamp HID Replace SEBU7763 03
6. Temperatures in this manual 6 Be sure that seals 1 are not pushed out Push back the seals if the seals are pushed out 7 Install plug 2 Note MPGM GREASE IS ALLOWED ONLY FOR A FAILED SEAL THE SEAL SHOULD BE REPLACED AS SOON AS POSSIBLE THE COMBINATION OF GEAR OIL AND MPGM IS NOT HARMFUL TO THE MACHINE When you operate the machine in arctic conditions lubricate the equalizer bar with EMGARD EP 75W90 gear lubricant EMGARD EP 75W90 gear lubricant is a synthetic lubricant This lubricant is available from Hudson Corporation See Operation and Maintenance Manual Lubricant Viscosities for more information 102093902 Equalizer Bar End Pins Measure SMCS Code 7206 082 Illustration 250 g00517058 To check the equalizer bar end pin for movement and unusual wear perform the following steps Note All weight of the machine must be removed from the equalizer bar Equalizer bar must have free movement in order to be measured 1 Clean the areas that are around the end pin with a high pressure wash Inspect the condition of the seal 2 Check the area for oil leakage and a neutral seal position 3 Install a dial indicator and measure the vertical play at both end pin joints 4 Check the oil in both end pin joints Note Schedule the end pin joint for repair if movement exceeds 1 50 mm 059 inch Consult your Caterpillar dealer for an inspection and for repair instructions 1
7. Test SEBU7763 03 101957816 Backup Alarm Test SMCS Code 7406 081 In order to test the alarm for proper functioning turn the engine start switch to the ON position Illustration 187 g01017699 Apply the service brake Release the parking brake Move the transmission direction selector to the REVERSE position The backup alarm should start to sound immediately The backup alarm will continue to sound until the transmission gear selector is moved to the NEUTRAL position or to the FORWARD position Olli ALLEIN Illustration 188 g01017684 The backup alarm is on the rear of the machine The nonadjustable backup alarm is set at the appropriate sound level when the machine is shipped from the factory i03613865 Battery Inspect SMCS Code 1401 040 Battery Inspect Illustration 189 g01117295 1 Open the battery access covers The battery access covers are located on the left side of the machine outside the operator compartment Illustration 190 g01117315 2 Tighten the battery retainers Clean the top of the batteries with a clean cloth Keep the terminals clean and coated with petroleum jelly Install the terminal covers after you coat the terminals 3 Close the battery access covers SEBU7763 03 133 Maintenance Section Battery Battery Cable or Battery Disconnect Switch Replace 102019456 Battery Battery Cable or Battery Disconnect Switch
8. bit is worn install a new end bit Note When the end bit is within 10 mm 0 4 inch of the bottom of the support change the end bit When the end bit is within 10 mm 0 4 inch of the outside edge of the support change the end bit Do not allow any wear to occur on the support 7 Install all bolts and tighten the bolts to a torque of 1150 150 N m 850 110 Ib ft Refer to Specifications SENR3130 Torque Specifications Torques for Ground Engaging Tools SEBU7763 03 149 Maintenance Section Electronic Unit Injector Inspect Adjust 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 proper torque 102061807 Electronic Unit Injector Inspect Adjust SMCS Code 1290 025 1290 040 The Electronic Control module produces high voltage To prevent personal injury make sure the Electronic Control Module is not powered and the unit injector solenoids are disconnected NOTICE The camshafts must be correctly timed with the crank shaft before an adjustment of the unit injector lash is made The timing pins must be removed from the camshafts before the crankshaft is turned or damage to the cylinder block will be the result The operation of Caterpillar engines with improper adjustments of the electronic unit injector can reduce engine efficiency This reduced efficiency could result i
9. ecceeeeeeeeereeeees 199 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 Obtain 2s eset eee eek teen EEA A E AA 142 Electronic Unit Injector Inspect Adjust 149 Engine Valve Lash Check Adjust c eee 159 Engine Valve Rotators Inspect isese 159 Winch Oil and Breather Change Clean 200 Every 500 Service Hours Engine Crankcase Breather Clean 151 Engine Oil and Filter Change n se 156 Final Drive Oil Sample Obtain 0 005 163 Fuel System Primary Filter Clean Replace 169 Fuel System Secondary Filter Replace 171 Fuel Tank Cap Filter and Strainer Replace Clean cccceeceeeeetccceceeeeeeeeteeeeeeeeens 172 Hydraulic System Oil Filters Replace 179 Hydraulic System Oil Sample Obtain 181 Power Train Breather Clean 184 Power Train Oil Filters Replace 2005 184 Power Train System Oil Sample Obtain 189 Recoil Spring Compartment Oil Level Check 191 Steering Charge Filter Replace 005 194 SEBU7763 03 131 Maintenance Section Maintenance Interval Schedule Every 1000 Service Hours or 6 Months Battery INS pett n aa Ena GA 132 Power Train System Oil And Screens Change Clean aasiiesseesssnesesrisseerrisdeennesens 186 Rollover
10. frame relative to the rear roller frame Illustration 333 g01021588 Some components are removed for clarity 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 i ei an T GE a i ih Illustration 334 g01021579 2 Use a grease pencil to make a mark on the tubular section of the front roller frame Make a mark on the rear of the roller frame This mark should correspond with the mark that is on the tubular section i oo Illustration 335 g01021605 Some components are removed for clarity SEBU7763 03 199 Maintenance Section Walk Around Inspection 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 o Bo ANY Ua pes SS L A i Illustration 336 g01021583 4 Put a mark on the tubular section of the front roller frame This mark should correspond with the mark on the rear roller frame M
11. Protective Structure ROPS Inspect 193 Winch Oil and Breather Change Clean 200 Every 2000 Service Hours or 1 Year Engine Mounts and Equalizer Bar Inspect 152 Final Drive Oil Change 162 Final Drive Seal Guard Packing Replace 164 Hydraulic System Oil Change n 176 Hydraulic System Oil Filter Pilot Replace 178 Radiator Guard Pin Joint Inspect 190 Track Roller Frame Inspect 000seeee 198 Track Roller Frame Guides Inspect 198 Every Year Cooling System Coolant Sample Level 2 Obtain ie tees il eee aa 142 Engine Air Filter Primary and or Secondary Element Clean Replace 20 0 2 cccceeseeeseceeceeeeeeeeeeeeeeneeees 149 Refrigerant Dryer Replace a e 192 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace ccccccceeeeeeeeeeeeeteeeeeeees 194 Every 4000 Service Hours Electronic Unit Injector Inspect Adjust 149 Engine Valve Lash Check Adjust eee 159 Engine Valve Rotators Inspect cee 159 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 145 Cooling System Water Temperature Regulator Replace tied sierra Adee enth iets awed 148 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 143 132 Maintenance Section Backup Alarm
12. 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 inside the left engine access door 4 Disconnect the negative battery cable at the battery 5 Replace the disconnect switch the battery cables or the batteries as required 6 Connect the negative battery cable at the battery 7 Connect the negative battery cable at the battery disconnect switch 8 Install the key and turn the battery disconnect switch to the ON position Battery Recycle 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 102229215 Belt Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Your engine is equipped with a serpentine belt that drives the alternator and the air conditioner compressor if equipped This engine is equipped with a belt tightener that automatically adjusts the belt to the correct tension Inspect 1 Park the machine on level ground Lower the dozer blade to the ground Move the transmission control to the NEUTRAL position and engage the parking brake Shut off the engine 2
13. Turn the battery disconnect switch to the OFF position 3 Open the engine access doors on the right side Illustration 191 g01117063 134 Maintenance Section Bottom Guard Power Clean SEBU7763 03 g01017579 Illustration 192 Front and left side view 1 Belt tensioner 2 Alternator reference only 3 Air conditioner compressor reference only 4 Serpentine belt 5 Idler pulley reference only 6 Alternator guard reference only 4 Inspect the condition of serpentine belt 4 Replace the serpentine belt if excessive wear or cracking has occurred Wear due to belt slippage indicates that the belt tensioner possibly needs to be replaced oa Close the engine access doors o Turn the battery disconnect switch to the ON position Replace 1 Park the machine on level ground Lower the dozer blade to the ground Move the transmission control to the NEUTRAL position and engage the parking brake Shut off the engine 2 Turn the battery disconnect switch to the OFF position 3 Open the engine access doors 4 Turn belt tensioner 1 in order to release the tension from the belt with a square drive 5 Remove the belt 6 Install the new belt 7 Close the engine access doors 8 Turn the battery disconnect switch to the ON position 102248240 Bottom Guard Power Clean SMCS Code 7153 070 NOTICE Do not operate the machine with the guard in the lower
14. application of the machine If a sample does not pass the oil analysis take one of these actions e Shorten the oil change interval to 250 hours e Proceed to Program B e Change to a preferred oil type in Table 21 Program B Optimizing Oil Change Intervals Begin with a 250 hour oil change interval The oil change intervals are adjusted by increments Each interval is adjusted an additional 50 hours Periodic oil sampling and analysis is done during each interval The analysis includes oil viscosity and infrared IR analysis of the oil Repeat Program B if you change the application of the machine If an oil sample does not pass the analysis shorten the oil change interval or change to a preferred multigrade oil type in the listing above References Reference Form PEDP7035 Optimizing Oil Change Intervals Reference Form PEDP7036 S O S Fluid Analysis Reference Form PEHP7076 Understanding the S 0 S Oil Analysis Tests Procedure for Changing the Engine Oil and Filter 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 Specia
15. defined as a function of fuel consumption rate High load factors can shorten the service life of your engine oil Continuous heavy load cycles and very little idle time result in increased fuel consumption and oil contamination These factors deplete the oil additives more rapidly If the average fuel consumption of your D8T exceeds 51 L 13 5 US gal per hour follow the High Load Factor recommendations in Table 21 To determine average fuel consumption measure average fuel consumption for a period of 50 to 100 hours If the application of the machine is changed the average fuel consumption may change 4 In order to verify an oil change interval of 500 hours refer to Program A below 5 Use Program B below to determine an appropriate interval Adjustment of the Oil Change Interval Note Your Caterpillar dealer has additional information on these programs Program A Verification for an Oil Change Interval of 500 Hours SEBU7763 03 157 Maintenance Section Engine Oil and Filter Change This program consists of three oil change intervals of 500 hours Oil sampling and analysis is done at 250 hours and 500 hours for each of the three intervals for a total of six oil samples The analysis includes oil viscosity and infrared IR analysis of the oil If all of the results are satisfactory the 500 hour oil change interval is acceptable for the machine in that application Repeat Program A if you change the
16. from a used filter 4 Install the cover plate Reference Refer to Lubricant Viscosities in the Maintenance Section of this manual for the correct fluid for your machine Reference Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Oil Analysis for information that pertains to obtaining a sample of the final drive oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the final drive oil 102774981 Final Drive Seal Guard Packing Replace If Equipped SMCS Code 4052 510 The design of the seal guard has a packing that prevents debris from entering the area of the Duo Cone Seal Gp The close fit and tolerances limit the size of the debris that can enter the labyrinth seal to 2 mm 0 079 inch The labyrinth seal changes the direction of the debris four times Contact may be made at the packing after the fourth time The packing material is impregnated with silicone oil Therefore it is not necessary to fill the cavity for the packing with grease The packing is held in place by retainers that can be removed This allows the replacement of the packing without removing the final drive The packing has a split that allows the packing to be placed over the spindle Replacement of the Packing Illustration 256 g00939700 4 Bolt 5 Washer 6 Retainer 1 Remove bolts 4 and wash
17. housing Illustration 224 g00470240 5 Remove the secondary filter element Pull out in order to remove the element SEBU7763 03 151 Maintenance Section Engine Air Precleaner Clean 6 Install a new secondary filter element Push the element firmly in order to properly seat the element Write the date on the element if the element is replaced 7 Install the primary filter element and the air cleaner housing cover 8 Close the engine access door if equipped 101959145 Engine Air Precleaner Clean SMCS Code 1055 070 Illustration 225 g01018245 1 Inspect the screen in engine air precleaner 1 that sits above engine hood 3 for dirt accumulation 2 Loosen retainer 2 and remove the screen 3 Clean the screen with compressed air or water 4 Replace the screen 102760299 Engine Crankcase Breather Clean SMCS Code 1317 070 1 Stop the engine Open the left access door Illustration 226 g01124723 Top view 2 Loosen the hose clamps on the outlet hose from the breather Remove the hose from the breather assembly 3 Remove the clamp from the base of the breather assembly 4 Lift up on the breather assembly in order to remove the assembly 5 Check the condition of the cover seal Replace the cover seal if the cover seal is damaged 6 Clean the breather in a clean nonflammable solvent 7 Shake the breather until the breather is dry You may also use
18. inspection procedure for the seat belt extension 102429594 Seat Belt Replace SMCS Code 7327 510 Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor 4 g01152685 Illustration 323 1 Date of installation retractor 2 Date of installation buckle 3 Date of manufacture tag fully extended web 4 Date of manufacture underside buckle Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware If your machine is equipped with a seat belt extension also perform this replacement procedure for the seat belt extension 102773461 Steering Charge Filter Replace SMCS Code 431F 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 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Di
19. maximum air pressure of 205 kPa 30 psi Direct the air from the clean side to the dirty side In order to show that the filter element has been cleaned mark the element The primary filter element can be cleaned up to six times NOTICE Do not clean the filter elements by bumping or tapping them Do not use filter elements with damaged pleats gaskets or seals Do not wash the filter elements 9 Push the filter element firmly in order to properly seat the element Write the date on the element if the primary element is replaced 10 Install the air cleaner cover 11 Close the access door if equipped Secondary Filter NOTICE Always replace the secondary filter element Never attempt to reuse it by cleaning The secondary filter element should be replaced at the time the primary element is serviced for the third time The secondary filter element should also be replaced if the yellow piston in the filter element indicator en ters the red zone after installation of a clean primary element or if the exhaust smoke is still black NOTICE The filter should be kept in service for no longer than one year NOTICE Always leave the secondary filter element in place while you clean the air cleaner housing 1 Open the engine access door if equipped 2 Remove the air cleaner housing cover 3 Remove the primary filter element Refer to the section Primary Filter 4 Clean the inside of the air cleaner
20. nozzle must be less than 205 kPa 30 psi for cleaning purposes N The filter element can be cleaned by using pressure air Use a maximum air pressure of 205 kPa 30 psi Direct the air from the clean side to the dirty side oO Look through the filter toward a bright light Inspect the element for damage Inspect the gaskets for damage Replace damaged filters 4 Install the filter element 5 Close the access covers Note Clean the filters more often in dusty conditions Cab Filter Fresh Air Clean Inspect Replace KPZ3226 UP SEBU7763 03 137 Maintenance Section Cab Filter Recirculation Clean Inspect Replace Illustration 199 g01770933 Note Use three point contact when you remove the cab filter fresh air Reference See Operation and Maintenance Manual Mounting and Dismounting for more information 1 The filter cover 1 is located near the top of the window on the left side of the cab Loosen three clamps 2 and remove the filter cover 2 Remove filter element 3 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 3 The filter element can be cleaned by using pressure air Use a maximum air
21. operation Before servicing remove power from lamp for at least five minutes to ensure lamp is cool NOTICE Although HID bulb materials may change over time HID bulbs produced at the time of the printing of this manual contain mercury When disposing of this com ponent or any waste that contains mercury please use caution and comply with any applicable laws 1 Remove the electrical power from the high intensity discharge lamp HID The electrical power must be removed from the HID lamp for at least five minutes in order to ensure that the bulb is cool SEBU7763 03 175 Maintenance Section Horn Test 2 Disassemble the housing for the HID lamp in order to have access to the bulb Note On some HID lamps the bulb is an integral part of the lens assembly The bulb is not removed separately from the lens assembly Replace the entire lens assembly on these HID lamps 3 Remove the bulb from the HID lamp 4 Install the replacement bulb in the HID lamp If the bulb is an integral part of the lens assembly install the replacement lens assembly in the HID lamp Note In order to avoid failure to the bulb that is premature avoid touching the bulb s surface with your bare hands Clean any fingerprints from the bulb with alcohol prior to operation 5 Reassemble the housing for the HID lamp Ensure that any printing on the lens is oriented correctly with respect to the HID lamp s mounting position on the
22. pressure air to dry the breather 8 Check the condition of the hose Make sure that the inside of the hose is unobstructed Replace the hose if the hose is damaged 9 Install breather assembly 2 10 Install clamp 3 11 Install the hose and breather outlet hose clamps 1 12 Open the doors to the radiator grill Examine the bottom of the breather Remove any debris that is clogging the breather tube 13 Close the doors to the radiator grill 14 Close the left access door 152 Maintenance Section Engine Mounts and Equalizer Bar Inspect SEBU7763 03 102195435 Engine Mounts and Equalizer Bar Inspect SMCS Code 1152 040 7206 040 Engine Mounts Caterpillar recommends checking the engine mounts for deterioration This will prevent excessive engine vibration that is caused from improper mounting Equalizer Bar End Pins Personal injury or death can occur from not fol lowing the proper procedure or the recommended tooling To prevent the possibility of injury or death follow the established procedure using the recommend ed tooling NOTICE The machine must be parked on a level surface to perform this procedure Personal injury or death can occur from not fol lowing the proper procedure or the recommended tooling To prevent the possibility of injury or death follow the established procedure using the recommend ed tooling NOTICE The machine must be parked on a level surface
23. pressure of 205 kPa 30 psi Direct the air from the clean side to the dirty side 4 Look through the filter toward a bright light Inspect the element for damage Inspect the gaskets for damage Replace damaged filters 5 Install filter element 3 and install filter cover 1 Close three clamps 2 Note Use three point contact when you install the cab filter fresh air Note Clean the filters more often in dusty conditions 101971627 Cab Filter Recirculation Clean Inspect Replace SMCS Code 7342 040 7342 070 7342 510 The recirculation filter is positioned to the left of the operator s seat in the cab Illustration 200 g01023431 Top view of the inside of cab 1 Unscrew the bolt to the cover of the recirculation filter and remove the cover Remove the recirculation filter element 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 2 The recirculation filter element can be cleaned by using pressure air Use a maximum air pressure of 205 kPa 30 psi Direct the air from the clean side to the dirty side 3 Look through the filter toward a bright light Inspect the element for damage Inspect the gaskets for damage Replace damaged filte
24. prop erly remove the refrigerant from the air condition ing system Illustration 318 g01017640 Note The R 134a refrigerant dryer receiver should be replaced annually Extremely humid operating conditions may require more frequent replacement of the dryer The dryer should also be replaced if the air conditioning system has been leaking or if the system has been opened for service repair The in line dryer is accessible by removing the floor panel in the cab Reference For the correct procedure refer to Air Conditioning and Heating Service Manual SENR5664 or the Disassembly and Assembly Manual for your machine Note A qualified mechanic should replace the components of the refrigerant system since special tooling and training are required 101286780 Ripper Linkage and Cylinder Bearings Lubricate SMCS Code 6313 086 BD L4 D Illustration 319 g00681900 Lubricate twelve grease fittings six per side Use MPGM Grease i00925689 Ripper Tip and Shank Protector Inspect Replace SMCS Code 6808 040 6808 510 6810 6812 040 6812 510 If equipped SEBU7763 03 193 Maintenance Section Rollover Protective Structure ROPS Inspect 101961853 Rollover Protective Structure ROPS Inspect SMCS Code 7325 040 Illustration 320 g00550432 When the ripper tip is worn close to the shank re
25. seal is damaged Wipe the magnet in order to clean the plug Install the plug 8 Repeat Step 1 to Step 7 in order to change the oil in the other final drive For additional information about final drive oil see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 101959718 Final Drive Oil Level Check SMCS Code 4050 535 FLV Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Illustration 254 g01018451 1 Position one final drive so that oil level mark 1 is horizontal with the oil filler plug 2 2 Remove oil filler plug 2 3 The oil level should be at the bottom of the filler plug opening Add oil if necessary 4 Wipe the magnet in order to clean the plug 5 Install oil filler plug 2 6 Repeat Step 1 to Step 5 in order to check the oil level in the other final drive 102229659 Final Drive Oil Sample Obtain SMCS Code 3258 008 4011 008 4050 008 4050 SM 4070 008 4070 554 SM 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 a
26. 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 g01759106 Illustration 217 1 Observe the sight glass 1 in order to verify the level of the coolant If the coolant completely covers the sight glass the coolant level is okay If the coolant level is visible in the sight glass the coolant is low Add coolant in order to fill the system 2 If it is necessary to add coolant remove the filler cap 2 slowly in order to relieve the pressure Note The factory fill is Extended Life Coolant ELC Refer to Operation and Maintenance Manual SEBU6250 Caterpillar Machine Fluids Recommendations for additional information Maintaining the system as ELC is preferred See the sections Coolant Recommendations and ELC Cooling System Maintenance QOO Illustration 218 g00475722 SEBU7763 03 147 Maintenance Section Cooling System Coolant Level Check 3 Look into filler tube 1 Maintain the coolant level between area 2 and area 3 of the filler tube Adding coolant above this area of the filler tube will cause the coolant to overflow the cooling system If you need to add coolant daily check the cooling system for leaks 4 Inspect the filler cap and the filler cap seal for debris for foreign material or for damage
27. to perform this procedure Note All the weight of the machine must be removed from the equalizer bar Equalizer bar must have free movement in order to be measured To check the equalizer bar end pin for movement and unusual wear perform the following steps Illustration 227 g01108793 1 Clean the areas that are around the end pin with a high pressure wash Inspect the condition of the seal 2 Check the area for oil leakage and a neutral seal position 3 Check the oil in both end pin joints Illustration 228 g01108795 4 Position a dial indicator on the bracket for the pin on the roller frame Set the dial indicator probe on top of the equalizer bar Set the dial indicator to zero SEBU7763 03 153 Maintenance Section Engine Mounts and Equalizer Bar Inspect Illustration 229 g01108798 5 Put a 55 ton hydraulic jack in position under the end of the equalizer bar 6 Jack up the equalizer bar and take a reading on the dial indicator in order to determine the amount of wear Note Schedule the end pin joint for repair if the reading on the dial indicator exceeds 1 50 mm 059 inch 7 Repeat the inspection and the measurement procedure for the other end of the equalizer bar and end pin Consult your Caterpillar dealer for an inspection and for repair instructions Equalizer Bar Center Pin Personal injury or death can occur fro
28. 01959542 Ether Starting Aid Cylinder Replace SMCS Code 1456 510 CD Breathing ether vapors or repeated contact of ether with skin can cause personal injury Person al injury may occur from failure to adhere to the following procedures Use ether only in well ventilated areas Do not smoke while changing ether cylinders Use ether with care to avoid fires Do not store replacement ether cylinders in living areas or in the operator s compartment Do not store ether cylinders in direct sunlight or at temperatures above 49 C 120 F Discard cylinders in a safe place Do not puncture or burn cylinders Keep ether cylinders out of the reach of unautho rized personnel To avoid possible injury be sure the brakes are ap plied and all controls are in Hold or Neutral when starting the engine 162 Maintenance Section Final Drive Oil Change SEBU7763 03 Illustration 251 g01018416 1 Open the engine access door if equipped on the left side of the machine The ether canister is mounted inside the compartment on the side of the engine Illustration 252 g01018418 2 Loosen the retaining clamp Remove the old canister by turning the canister counterclockwise 3 Remove the old gasket Install the new gasket 4 Install the new canister Turn the canister clockwise Hand tighten the canister Tighten the clamp around the canister 5 Close the engine access do
29. 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 1 If the oil level on dipstick 2 indicates that oil is needed remove filler cap 1 and add the oil 2 Clean the filler cap and install the filler cap 3 Close the access door 103644992 Power Train System Oil Sample Obtain SMCS Code 3080 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 Dealer Service Tool Catalog 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 S 0 S oil analysis you must establish a consistent trend of data In
30. 3644991 Power Train System Oil Level Check SMCS Code 3030 535 FLV Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Illustration 309 g01019160 Some components are removed for clarity The transmission oil dipstick is behind the access door on the right side of the operator s station Open the access door and check the transmission oil level SEBU7763 03 189 Maintenance Section Power Train System Oil Sample Obtain Hot Oil I OPR_ZONE 16L TRANSMISSION IN NEUTRAL ENG NE AT LOW IDLE AND OIL AT OPERATING TEMPERATURE Illustration 310 g00493905 Use the TRANSMISSION IN NEUTRAL ENGINE AT LOW IDLE AND OIL AT OPERATING TEMPERATURE side of the dipstick 2 Check when the transmission is in NEUTRAL and the engine is running at LOW IDLE The oil should be at operating temperature Maintain the oil level between the OPERATING ZONE marks This is the only accurate way to check the oil level Cold Oil I OPR ZONE 16L ENGINE STOPPED COLD OIL Illustration 311 g00493912 Check the ENGINE STOPPED COLD OIL side of dipstick 2 while the engine is stopped Maintain the oil between the OPERATING ZONE marks This method should be used as reference only Note When you are operating the machine on severe slopes the quantity of oil in the transmission can be increased up to
31. 59 Maintenance Section Engine Valve Lash Check Adjust 102763245 Engine Valve Lash Check Adjust SMCS Code 1102 025 1102 To prevent possible injury do not use the starter motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring valve clearance Electrical shock hazard The electronic unit injec tor system uses 90 120 volts NOTICE Operation of Caterpillar engines with improper valve adjustments will reduce engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life NOTICE Measure the valve clearance with the engine stopped To obtain an accurate measurement allow at least 20 minutes for the valves to cool to engine cylinder head and engine block temperature Check the valve bridge before setting the valve lash Ensure that the valve bridge is seated equally on both valve stems Refer to your machine s Service Manual or your Caterpillar dealer for the complete valve adjustment procedure 102763340 Engine Valve Rotators Inspect SMCS Code 1109 040 When inspecting the valve rotators protective glasses or face shield and protective clothing must be worn to prevent being burned by hot oil or spray Electrical shock hazard The electronic unit injec tor system uses 90 120 volts A WARNING Illustration 244 g00941949 1 Start the e
32. Clean the filler cap with a clean cloth Replace the radiator cap if the filler cap is damaged 5 Install the filler cap 6 Inspect the radiator core for debris Clean the radiator core if necessary Illustration 219 g01117259 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 Allow the radiator cores to dry completely before operating the machine in the work mode Wood Chip or Waste Handling Arrangement If Equipped Clean the Radiator Cores 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 NOTICE Pressurized air To avoid possible engine damage shut off engine before performing maintenance to clean the cooling system Install air nozzle into access slot before starting air supply Read and understand Operation and Maintenance Manual Illustration 220 g01382652 Wood chip or waste handling arrangement if equipped Some components are removed for clarity Use 307 6728 Air Nozzle 1 not shown in order to clean debris from the cooling system Use the work tool safely 1 Turn off the engine a Make sure that the fan has stopped
33. IDPDP DDD DiI LDIDD ID ih g01021628 Illustration 331 1 During the machine operation listen for unusual squeaking and for unusual squealing This can indicate a dry joint 2 Check the machine for dry joints weekly Check for dry joints immediately after machine operation After machine operation lightly touch the end of each track pin or bushing Touch the track pin or the track bushing with the back of your hand Make a mark on any dry track pin joint that is very hot to the touch 198 Maintenance Section Track Roller Frame Inspect SEBU7763 03 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 dealer s Custom Track Service expert if you detect dry joints or leaks Your Caterpillar dealer s Custom Track Service expert can perform track inspection 102039992 Track Roller Frame Inspect SMCS Code 4151 040 Illustration 332 g0 1049034 Inspect the track roller frame 3 for leaks Check the seal for the pivot shaft 2 for oil leaks Check the idlers 1 and track rollers 4 for leaks Inspect the seal for the recoil spring 5 for oil leaks 101967485 Track Roller Frame Guides Inspect SMCS Code 4177 040 Measure the rotational movement of the front roller
34. Kit to check the concentration of the coolant Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand Cooling System Conditioner contains alkali Avoid contact with skin and eyes g01757656 Illustration 215 1 The filler cap is located inside the access door on the top left side of the radiator guard Loosen the radiator cap slowly in order to relieve pressure Remove the radiator cap 2 It may be necessary to drain some coolant from the radiator so that Extender can be added to the cooling system Note Always discard drained fluids according to local regulations NOTICE 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 com ponent 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 regula
35. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR SES y 208 Operation and Maintenance Manual D8T Track Type Tractor J8B1 Up Machine KPZ1 Up Machine 130 Maintenance Section Maintenance Interval Schedule SEBU7763 03 102877581 Maintenance Interval Schedule SMCS Code 7000 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Note Before each consecutive interval is performed all maintenance from the previous interval must be performed When Required Battery Battery Cable or Battery Disconnect Switch Replace E sete ae aera al eite hate 133 Bottom Guard Power Clean i e 134 Cooler Cores and A C Condenser Clean 138 Cuttin
36. System Coolant Level Check 146 Engine Oil Level Check c cc cceeeeeeeeeeeeeneeeees 154 Fuel System Primary Filter Water Separator DY ienai A AA le dete eee ed 170 Fuel Tank Water and Sediment Drain 173 Horn Test istir 175 Hydraulic System Oil Level Check 0 180 Indicators and Gauges Test 2 0 181 Pivot Shaft Oil Level Check 183 Power Train System Oil Level Check 188 Seat Belt Inspect 20 0 ceeeeeeeeeeeeeeeceeeeeeeeeees 193 Walk Around Inspection ceeceeeeeeeeeeeees 199 Every 50 Service Hours Bulldozer Tilt Brace and Tilt Cylinders Lubricate ain eile nadie eee ae 135 Cab Filter Recirculation Clean Inspect Replace iiini a a iaae eta a a 137 Lift Cylinder Yoke Bearings Lubricate 182 Ripper Linkage and Cylinder Bearings FUDIIGAtE E E cee es iia ks ce ted assente ence ena eee 192 Track Pins Inspect cccceeeeeeeeeeeeeeeeeteaees 197 Every 250 Service Hours Belt Inspect Adjust Replace eeee 133 Engine Oil Sample Obtain asainne 155 Engine Oil and Filter Change ee 156 Equalizer Bar End Pins Oil Level Check 160 Final Drive Oil Level Check cceeeeeee 163 Track Check AdjuSt 00 eecccceeeeeseeeeeeeestteeeeeeeaaes 195 Winch Fairlead Rollers Lubricate 199 Winch Oil Level Check
37. act your Caterpillar dealer for track service or instructions 1 Remove the access cover Illustration 330 g01019116 2 Add multipurpose grease MPGM through track adjustment valve 1 Add the MPGM until dimension A B C is correct 3 Operate the machine back and forth in order to equalize the pressure Allow the machine to coast to a complete stop Do not use the brakes 4 Remeasure dimension D Tight Track Adjustment 1 Loosen relief valve 2 by one turn of 360 degrees Allow the grease to escape 2 Close the relief valve 3 Add MPGM through track adjustment valve 1 Add grease until dimension A B C is correct 4 Install the access cover Bolt Torque for Track Shoes The torque requirement for track shoe bolts is 650 70 N m 480 50 Ib ft Tighten the bolts for an additional 120 degrees If you are using bolts with a master link tighten the bolts to a torque of 650 70 N m 480 50 Ib ft Then tighten the bolts for an additional 120 degrees 101967541 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 _ e pm DADDMIR
38. ain the oil into a suitable container 3 NA CI Illustration 304 g01023184 7 Remove the access cover 3 to the drain for the transmission not shown Remove plug 6 in the guard for access to the drain valve 8 Remove plug 5 from the drain valve in the transmission Install a 12 7 mm 5 inch pipe into the transmission valve Use a 12 7 mm 0 50 inch pipe with 1 2 14 NPTF threads Clamp a hose to the pipe in order to drain the oil into a suitable container 9 Open drain valve 4 and drain the oil into a suitable container 10 Change the filter element See the Topic Transmission System Oil Filter Replace in this manual 11 Close the drain valve in the torque converter Close the drain valve in the transmission case 12 Remove the hoses and remove the pipes from the drains 13 Remove the swivel or remove the pipe from the drain in the bevel gear case The drain valve will close 14 Clean the oil drain plugs and install the oil drain plugs Clean Screens Screens should be removed and cleaned when the oil is drained Drain the oil into a suitable container before removing any screen g01124858 Illustration 305 1 Remove torque converter scavenge line 7 Remove the screen Car Illustration 306 g01356854 2 Remove cover 8 from the transmission scavenge screen Remove the screen 188 Maint
39. an to run until the cooling system has completely dried Allow the machine to sit overnight before operating the machine in the work mode Wood Chip or Waste Handling Arrangement If Equipped Cooler Cores The wood chip and waste handling arrangements have a remote mounted a c compressor and a single plane of the following cores hydraulic oil cooler core AMOCS radiator cores and aftercooler core Additionally these arrangements have a hydraulic fan that reverses the direction of air flow in order to purge debris Clean 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 NOTICE Pressurized air To avoid possible engine damage shut off engine before performing maintenance to clean the cooling system Install air nozzle into access slot before starting air supply Read and understand Operation and Maintenance Manual SEBU7763 03 141 Maintenance Section Cooler Cores and A C Condenser Clean In applications with high levels of airborne debris a regular schedule for cleaning the cooling cores must be established The frequency of cleaning and the method of cleaning must be tailored to the specific debris accumulation on the job site In order to maintain clean cores the cleaning
40. ance Section Pivot Shaft Oil Level Check 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 103079214 Pivot Shaft Oil Level Check SMCS Code 4153 535 FLV Illustration 294 g01562554 Oil must be visible through the sight gauge 1 Open the access door 2 to the battery box on the left fender Illustration 295 g01561896 Top view To fill the reservoir add oil through the dipstick opening 3 m g01562774 Illustration 296 Maintain the oil within the FULL 4 and the ADD 5 limits of the dipstick for the oil reservoir Do not over
41. and the a c condenser core Also clean the space between the hydraulic oil cooler and the AMOCS radiator cores Use a bent copper tube that is approximately 1 4 3 8 inch diameter as an extension to the air nozzle This will facilitate cleaning of the middle spaces Do not use steam or high pressure water for cleaning frequently If steam or high pressure water is required to dislodge any debris that is held deep in the cores make sure that the cleaning is thorough This may require partial removal or total removal of the hydraulic oil cooler and the air conditioner condenser for better access Incomplete cleaning with water may cause remaining debris to harden in place Use lights and wire probes in order to ensure that the cleaning is thorough and complete If the debris has hardened in the center of the cores these cores may need to be removed for thorough cleaning If you use a degreaser and steam for removal of oil and grease wash the core with detergent and hot water Thoroughly rinse the core with clean water Dry the cores completely before operating the machine in the work mode Dry If steam or water is used to clean the cores make sure that the cores are completely dry before the track type tractor is put back to work Use compressed air to blow dry the wet cores the engine engine access doors and the hood Close both engine access doors If the machine is in a clean environment start the engine and allow the f
42. aning area park the machine in NEUTRAL and engage the parking brake 2 Depress the fan control switch and hold for three seconds in order to enter the continuous reverse mode Run the fan in the reverse mode continuously for 2 minutes 3 Turn off the engine Make sure that the fan has stopped rotation 142 Maintenance Section Cooling System Coolant Sample Level 2 Obtain SEBU7763 03 4 Open both of engine access doors 1 Use a regular air nozzle to clean the cores from the rear side Blow off the hood engine access doors and the entire engine compartment On machines that are equipped with the woodchip arrangement open the grill doors and blow off the shelf of the radiator guard 5 Open the cover to access slot 6 on both sides of the radiator guard Insert the 307 6728 Air Nozzle into the access slot on the right side of the machine in order to clean the cores on the left side of the machine Note Cleaning the cores from the opposite side of the machine allows better cleaning in the corners 6 Turn on the air supply Note Do not activate the air supply until you have inserted the air nozzle into the access slot Use the work tool safely 7 Move the air nozzle in a pattern in order to clean the cores from the front side of the cores Blow out the cores on the left side of the cooling system 8 Turn off the air supply when the nozzle cleaning of the left side cores is completed 9 Remove the air
43. ation index marks as a guide Note Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter 8 Coat the seal of the water separator bowl with clean diesel fuel Install the water separator bowl to the filter element 9 Turn the red lever 1 in order to resume the fuel supply 10 Prime the fuel system See the Topic Fuel System Prime in this manual 11 Start the engine and run the engine Check filter 2 and water separator bowl 3 for leaks 12 Close the engine access door 101969397 Fuel System Primary Filter Water Separator Drain SMCS Code 1263 543 Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately 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 disa
44. ays 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 Reference Refer to Disassembly and Assembly Water Temperature Regulator Remove and Disassembly and Assembly Water Temperature Regulator Install for more information Fill the engine cooling system Refer to Operation and Maintenance Manual Caterpillar Machine Fluids Recommendations and Operation and Maintenance Manual Capacities Refill 101959143 Cutting Edges and End Bits Inspect Replace SMCS Code 6801 040 6801 510 6804 040 6804 510 Illustration 221 g01018242 1 Raise the bulldozer blade and block up the bulldozer blade When you remove the cutting edges and the end bits maintain the bulldozer blade at a minimum height 2 Remove the bolts Then remove the cutting edge and the end bits 3 Thoroughly clean all contact surfaces 4 Inspect the opposite side of the cutting edge If the opposite side of the cutting edge is not worn turn the opposite side of the cutting edge outward and install the cutting edge 5 If both sides of the cutting edge are worn install a new cutting edge section Note When the cutting edge is within 10 mm 0 4 inch of the bottom of the support change the cutting edge Do not allow wear to occur on the support 6 If the bottom edge or the outside edge of the end
45. e guard 7 Position the jack under the guard prior to replacing the bolts The head of the jack should not be touching the guard 8 Install the bolts 101958206 Braking System Test SMCS Code 4100 081 4267 081 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 Note The machine can drive through the brakes in first gear 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 1 Start the engine 2 Raise all attachments Illustration 195 g01017767 3 Depress the brake pedal 4 Release the parking brake 5 While the brake pedal is depressed move the directional control to the SECOND SPEED FORWARD position 6 Gradually increase the engine speed to full load speed The machine should not move 7 Move the directional control to the NEUTRAL position 8 Reduce the engine speed to LOW IDLE Engage the parking brake Lower all attachments to the ground Apply a slight down pressure Stop the engine NOTICE If the machine moved while testing the brakes contact your Caterpillar dealer Have the dealer inspect and if n
46. e Section SEBU7763 03 Engine Air Filter Primary and or Secondary Element Clean Replace 2 Remove the air cleaner cover 1 Pull out in order to remove the element 3 Remove the primary filter element 2 from the air cleaner housing 4 Mark the secondary filter element in order to show that the primary filter element has been serviced The secondary filter element should be replaced when the primary filter element is serviced for the third time Refer to the section Secondary Filter Illustration 223 g00470857 5 Clean the inside of the air cleaner housing Keep the secondary filter element in place while you clean the housing 6 If the primary filter element has not been cleaned six times inspect the primary filter element If the primary filter element has been cleaned six times replace the primary filter element Proceed to Step 9 7 Inspect the primary filter element Inspect the filter element for holes and for tears by looking through the filter element Look toward a bright light Inspect the element for damaged gaskets or for dented metal parts Replace damaged filters Always crush damaged filter elements Properly discard the filter elements If you replace the primary filter element proceed to step 9 8 If the primary filter element is not damaged and the element has not been previously cleaned six times clean the element The filter element can be cleaned by using pressure air Use a
47. e parking brake and stop the engine 1 Make sure that all work tools are lowered to the ground Illustration 279 g01022926 Cross section view 2 Remove hydraulic tank filler cap 1 slowly in order to relieve any pressure 3 Wash the filler strainer and the filler cap in a clean nonflammable solvent 4 Remove oil drain plug cover 3 that is under the hydraulic tank Illustration 280 g01022927 4 Oil drain plug 5 Sight gauge 5 Remove the oil drain plug The oil drain plug is located under right fender 4 6 Attach a hose to a 126 7914 Swivel Install the swivel and the hose into the drain plug opening A pipe nipple 10 cm 4 inch and a hose can also be used Use a 25 4 mm 1 inch pipe with 1 11 1 2 NPTF threads Do not tighten the pipe 7 Rotate the swivel clockwise in order to open the internal drain valve Allow the oil to drain into a suitable container 8 Remove the swivel The valve for the hydraulic tank will close 9 Clean the drain plug and install the drain plug Tighten the drain plug to a torque of 68 7 Nm 50 5 lb ft Install the oil drain plug cover 10 Change the hydraulic system filters Case drain filter 2 is shown See the Operation and Maintenance Manual Hydraulic System Oil Filters Replace 11 Install the filler strainer 12 Fill the hydraulic oil tank See the Operation and Maintenance Manual Capacities Refill in order to determi
48. ean SMCS Code 7310 070 7340 070 If equipped Use commercially available window cleaning solutions to clean the windows To clean the outside of the rear window from the inside of the cab remove the sliding section of the rear window Use the following procedure in order to remove the sliding section of the rear window Illustration 344 g00039956 Lift latch 1 in order to slide the small window Squeeze latch 2 in order to move the window from the CLOSED position 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 Move the small 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
49. easure the distance between the two marks on the front roller frame If the distance between the two marks is greater than 4 5 mm 18 inch inspect the track roller frame guides for wear Repeat the entire procedure for the other side of the machine NOTICE Never build up the track roller frame guides with hard face welding This will cause serious wear damage to the guide slots in the front track roller frame LZ _ Illustration 337 g00785460 If dimension X is less than 45 3 mm 1 78 inch replace the track roller frame guides Consult your Caterpillar dealer for information or for service 103409088 Walk Around Inspection SMCS Code 1000 7000 Reference See Operation and Maintenance Manual Daily Inspection for more information 102112864 Winch Fairlead Rollers Lubricate SMCS Code 5163 086 If equipped Illustration 338 g01076211 Lubricate the five fittings Use MPGM Grease 102112874 Winch Oil Level Check SMCS Code 5163 535 FLV If equipped 200 Maintenance Section Winch Oil and Breather Change Clean SEBU7763 03 PA140VS PA140VS Illustration 339 g01076215 1 Remove oil level plug 2 in order to check the oil level The oil level should be maintained to the bottom of the level plug hole 2 If necessary remove oil filler plug 1 and add oil Check for oil leaks ar
50. eath one of the pins 4 Lower the bulldozer blade Apply sufficient down pressure in order to raise the front of the machine off the ground 5 If the travel of the indicator is more than 1 mm 0 04 inch replace the pin and replace the bushing 6 Check the other three pin locations Contact your Caterpillar dealer for service 103499636 Radiator Pressure Cap Clean Replace SMCS Code 1353 070 Z2 1353 510 Z2 Pressurized system Hot coolant can cause seri ous burn To open cap stop engine wait until ra diator is cool Then loosen cap slowly to relieve the pressure SEBU7763 03 191 Maintenance Section Recoil Spring Compartment Oil Level Check Illustration 315 g01835526 Rear view 1 Open the access cover to the radiator cap on top of the radiator guard Unlock the cover if necessary 2 Slowly remove the radiator cap in order to relieve system pressure 3 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 4 Install the radiator cap 101960703 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 Illustration 316 g01018614 1 Remove all of t
51. ecessary repair the service brake before returning the machine to operation 102229253 Bulldozer Tilt Brace and Tilt Cylinders Lubricate SMCS Code 5104 086 6050 086 6074 086 Lubricate the two fittings with CAT multipurpose type grease with molybdenum disulfide MPGM 136 Maintenance Section Cab Filter Fresh Air Clean Inspect Replace SEBU7763 03 Illustration 196 g01117177 One fitting is located at the left front brace assembly or left tilt cylinder if equipped The other fitting is located at the rod end of the right tilt cylinder i a Illustration 197 g01117220 All of the locations for the grease fittings on the angle blade are shown here The angle blade has an additional grease fitting that needs to be greased with MPGM Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations for more information about MPGM 103418420 Cab Filter Fresh Air Clean Inspect Replace SMCS Code 7342 040 7342 070 7342 510 Illustration 198 g01118586 1 Open the access cover to the filter element The filter cover is on the left side of the machine next to the battery compartment 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
52. ed position Damage to the machine or actuator could result The guard is heavy Personal injury or death may result from being struck by or trapped under the guard Do not allow anyone to work near or un der the machine when the guard is being raised or lowered Illustration 193 g01131971 The power guard control is located in a compartment on the left fender in front of the fuel tank The power guard control opens the bottom guards for easier access during cleaning y 5 A a Illustration 194 g01131976 SEBU7763 03 135 Maintenance Section Braking System Test NOTICE Do not activate switches for power guard control with out removing the bolts from the guard Damage to the actuator could result 1 Position a jack under the bottom guard in order to lower the guard The head of the jack should not be touching the guard 2 Remove the bolts from the bottom guard and move switch 1 downward in order to lower the guard If the guard lowers completely onto the jack it is possible that the actuator has failed Use the jack to support the guard and lower the guard to the ground 3 If the guard remains supported above the jack remove the jack 4 Lower the guard to the lowest position 5 Remove all foreign debris from the underside of the engine compartment 6 Move the switch upward in order to raise th
53. en ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Testing the coolant can be done at your Caterpillar dealer Caterpillar S O S Coolant Analysis is the best way to monitor the condition of your coolant and your cooling system S O S Coolant Analysis is a program that is based on periodic samples See Operation and Maintenance Manual SEBU6250 Cooling System Specifications General Coolant Information for more information Perform a Coolant Analysis Level 2 at initial 500 hours for systems that contain extended life coolant ELC Perform the analysis yearly after the initial 500 hours SEBU7763 03 143 Maintenance Section Cooling System Coolant ELC Change g g01755673 CAL a Illustration 210 1 Park the machine on a hard level surface Set the engine at low idle speed 2 Open the left side engine compartment Remove the protective cap from the sampling valve 3 Obtain a sample For additional information about coolant analysis see Operation and Maintenance Manual SEBU6250 Cooling System Specifications General Coolant Information or cons
54. enance Section Power Train System Oil Level Check SEBU7763 03 Illustration 307 g01356715 A Right side view B Front view 3 Remove cover 10 the seal and four bolts from the main suction line that is next to the power train oil pump 9 Remove main suction screen 11 4 Inspect the O ring seal If the seal is damaged replace the seal 5 Clean the three screens in clean nonflammable solvent 6 Install the screens Install the covers Fill With Oil 1 Open the access door for the filler cap The filler cap is located on the right side of the machine next to the hydraulic oil tank g01351984 Illustration 308 Some components are removed for clarity 2 Remove oil fill cap 13 3 Fill the bevel gear case with oil See Operation and Maintenance Manual Capacities Refill 4 Always measure the oil with the dipstick 12 5 Maintain the oil level within the OPR ZONE 16L marks on the dipstick The engine should be running at low idle The power train should be at operating temperature See Operation and Maintenance Manual Transmission System Oil Level Check for more information 6 Clean oil filler cap 5 Install the oil filler cap 7 Install the rear bottom guard For additional information about transmission system oil see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 10
55. ent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates The transmission oil filters are located on the right side of the machine behind the access cover that faces front of the machine Note The Caterpillar recommended filters are a special high efficiency design Use only the recommended filter Illustration 298 g01023030 1 Open the access door above the right fender Remove drain plugs 1 in order to remove a small amount of oil Use a wrench in order to remove filter housings 2 2 Remove the filter elements and properly discard the filter elements 3 Clean the filter element housings and clean filter bases 3 with a clean cloth 4 Inspect the seals If the seals are damaged replace the seals 5 Install new filter elements Install the filter element housing covers 6 Start the engine SEBU7763 03 185 Maintenance Section Power Train Scavenge Screen Clean g01023041 Illustration 299 Some components are removed for clarity 7 Check the oil HOT OIL Use the TRANSMISSION IN NEUTRAL ENGINE AT LOW IDLE AND OIL AT OPERATING TEMPERATURE side of the dipstick 4 Check when the transmission is in NEUTRAL and the en
56. epared 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 Illustration 290 g01018666 Obtain a sample of the hydraulic oil from the sampling valve The sampling valve is located behind the access door on the right side of the cab Remove the protective cap from the oil sampling port that is above the steering charge filter Refer to Special Publication SEBU6250 S O S Oil Analysis for information that pertains to obtaining a sample of the oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the oil For additional information about hydraulic system oil see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 102776749 Indicators and Gauges Test SMCS Code 7450 081 7490 081 If the action alarm does not sound during this test or machine monitoring displays are not function ing do not operate the machine until the cause has been corrected Machine operation with faulty action alarms or displays could resu
57. ers 5 Remove retainers 6 SEBU7763 03 165 Maintenance Section Final Drive Seal Guard Packing Replace XS Mj me Illustration 257 g00939529 Cross section view of seal guard 6 Retainer 7 Inner packing 9 Outer packing D 2 mm 0 079 inch 2 Inspect the packing and the seal guard for evidence of leaking through the packing Remove packing 6 and 9 from seal guard 3 Oil leakage through the packing would indicate leakage of the Duo Cone Seal Gp in the final drive Inspect the Final Drive for oil leakage through the Duo Cone Seal Gp If oil is leaking through the seal replace the Duo Cone Seal Gp Refer to the Service Manual Table 22 Required Parts Part Qty Description Number 137 9810 2 Seal packing 129 1928 1 Grease Note Each final drive seal guard requires two 137 9810 Seals packing The sections of packing are installed on top of each other in the groove of the seal guard Illustration 258 g00941695 7 Inner packing 8 Joint in the inner packing A Diameter A 3 Install inner packing 7 Place a thin film of 129 1928 Grease on diameter A Stretch the packing during installation Smooth the packing and keep the packing uniform Minimize the joint 8 at the ends of the inner packing 7 166 Maintenance Section Front Idler Position Check SEBU7763 03
58. ert 1 Park the machine on a hard flat surface Make 5 If excess vibration occurs after the undercarriage sure that the bottom track is tight and that the wear on the link and roller system exceeds measured grouser lies directly below the track 100 percent for machines with the SystemOne idler shaft Undercarriage add shims under the bogie pads in order to lower the rollers and raise the idlers 2 Measure the height A B from the flat ground as needed surface to the grouser tip that is centered below the track idler shaft Consult your Caterpillar dealer for detailed information about adjustments to the center tread 3 Maintain the grouser height rise to the following idler dimensions See Operation and Maintenance Manual Track a A Front Idlers Check Adjust for information on needed track adjustments Minimum 0 mm 0 inch Reference See Operation and Maintenance Maximum 45 mm 1 77 inch Manual Reference Material for publications and Special Instructions on removal and installation of b B Rear Idlers SystemOne Track as needed Minimum 10 mm 0 4 inch Maximum 60 mm 2 36 inch 4 Repeat Steps 1 through 3 in order to determine the proper height dimension under each idler 168 Maintenance Section Fuel System Prime SEBU7763 03 Center Tread Idler or Conventional Design Illustration 262 g01731594 A Adjusting shims B Dime
59. ess door if equipped For additional information about oil sampling see Operation and Maintenance Manual SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 156 Maintenance Section Engine Oil and Filter Change SEBU7763 03 102771121 Engine Oil and Filter Change SMCS Code 1308 1318 510 Selection of the Oil Change Interval NOTICE This machine is equipped with an engine that meets EPA Tier Ill Euro Stage Il or MOC Step 2 emission regulations A 500 hour engine oil change interval is available provided that operating conditions and rec ommended multigrade oil types are met When these requirements are not met shorten the oil change interval to 250 hours or use an S O S oil sampling and analysis program to determine an acceptable oil change interval If you select an interval for oil and filter change that is too long you may damage the engine CAT oil filters are recommended Abnormally harsh operating cycles or harsh environments can shorten the service life of the engine oil Arctic temperatures corrosive environments or extremely dusty conditions may require a reduction in engine oil change intervals from the recommendations in Table 21 Also refer to Manual SEBU5898 Cold Weather Recommendations for all Caterpillar Machines Poor maintenance of air filters or of fuel filters requires reduced oil change intervals See your Caterpillar deale
60. fill the oil reservoir Hot oil can overflow the reservoir Note The initial fill of the pivot shaft may trap air in the tube The level of the oil may fall as air escapes Barometric pressure may raise the oil level or the pressure may lower the oil level Changes in the altitude may raise the oil level or the altitude may lower the oil level The reservoir must be filled several times in order to remain consistently full Note Do not use the Vacuum Fill method 184 Maintenance Section Power Train Breather Clean SEBU7763 03 103644984 Power Train Breather Clean SMCS Code 3030 070 BRE g01019203 Illustration 297 Some components are removed for clarity 1 Open the access cover for the transmission filler tube on the right side of the cab The breather attaches to the filler tube on top of a 90 degree elbow Unscrew and remove the breather 2 Clean the breather in clean nonflammable solvent 3 Install the breather and close the cover 103644986 Power Train Oil Filters 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 disassembling any compo n
61. filler cap slowly in order to relieve any remaining pressure 1 TU 2 Dira u gm p i O C Bo 0006 as 5 Eo Illustration 275 g01943757 Front view of the hydraulic tank 1 Filler Cap 2 Relief Valve 3 Sight Gauge 4 Drain Plug 5 Press button 2 on the breaker relief valve in order to relieve any tank pressure Slowly remove filler cap 1 176 Maintenance Section Hydraulic System Oil Change SEBU7763 03 Illustration 276 g01943758 Top view of the Hydraulic Tank Illustration 277 g01943759 Bottom view of the Hydraulic Tank 5 Implement return port 6 Hydraulic tank access cover 7 Case drain return port 8 Suction port 6 Drain the hydraulic oil tank at drain 4 Reference For the correct procedure refer to Operation and Maintenance Manual Hydraulic System Oil Change 7 Disconnect the drain lines 8 Unbolt hydraulic tank access cover 6 Illustration 278 g01943760 Return screens 9 Implement return 10 Case drain return 9 Remove return screens that are within reach Clean the screens with a clean nonflammable solvent 10 Inspect the O ring seal if the casting is removed If the seal is damaged replace the seal 11 Replace the return screens 12 Replace hydraulic ta
62. g Edges and End Bits Inspect Replace 148 Engine Air Filter Primary and or Secondary Element Clean Replace 20 0 2 ccccceeeeeeeeeceeceeeeeeeeeeeeteeeeees 149 Engine Air Precleaner Clean ccce 151 Equalizer Bar Center Pin Measure 160 Equalizer Bar End Pins Measure 006 161 Ether Starting Aid Cylinder Replace 161 Front Idler Position Check ccceeeeeeeeeees 166 Fuel System Prime cceececceeeeeeeeeeenteeeeeeenaaes 168 Fuses and Circuit Breakers Replace Reset 173 High Intensity Discharge Lamp HID Replace 174 Hydraulic System Filter Screens Clean 175 Oil Filter Inspect ec eeeeceeeeeeeeeeeeeeeeeeeenteeeeees 182 Power Train Scavenge Screen Clean 185 Radiator Pressure Cap Clean Replace 190 Ripper Tip and Shank Protector Inspect Replace soiit ee iaraa e e a fe ent ed 192 Torque Converter Scavenge Screen Clean 195 Winch Wire Rope Install eeeeeeeeeeees 201 Window Washer Reservoir Fill 00006 201 Window Wipers Inspect Replace 0 0 202 Windows Clean ae u ia enaa aa daa stees ad antes 202 Every 10 Service Hours or Daily Backup Alarm Test ceeeeeeeeeeeeeeeeeeeeeeeeees 132 Braking System Test cceeceeseeeeeeesteeeeeeeneaes 135 Cab Filter Fresh Air Clean Inspect Replace 136 Cooling
63. gine is running at LOW IDLE The oil should be at operating temperature Maintain the oil level between the OPERATING ZONE marks This is the only accurate way to check the oil level COLD OIL Check the ENGINE STOPPED COLD OIL side of the dipstick 4 while the engine is stopped Maintain the oil between the OPERATING ZONE marks This method should be used as reference only 8 Remove filler cap 5 If necessary add oil 9 Clean the filler cap and install the filler cap 10 Close the access door 103644989 Power Train Scavenge Screen Clean SMCS Code 3030 070 MGS Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin When you change the transmission oil clean the scavenge screen Drain the oil before you remove any screens Illustration 300 g01067695 Note Ecology drains have been provided An ecology drain drains off the oil from the sump of the planetary transmission Remove the bottom plug Install a pipe with 1 2 14 NPTF threads and a rubber hose Drain the sump by backing out the valve until the oil begins to drain 1 Remove cover 1 the seal and transmission scavenge screen 2 from the bottom of the transmission 2 Wash the screen in a clean nonflammable solvent 3 Inspect the seal If the seal is damaged replace the seal 4 Install transmission scavenge screen 2 the seal and cover 1 o
64. he debris around the cover plate on the top of the track roller frame 2 Remove the cover plate for the oil filler Observe the level of the oil Illustration 317 g01110810 3 Maintain the oil level above the top of the track adjusting cylinder 1 Do not fill the oil above the track adjustment valve 2 4 Install the cover plate 5 Repeat the procedure for the other recoil compartment 192 Maintenance Section Refrigerant Dryer Replace SEBU7763 03 103649694 Refrigerant Dryer Replace SMCS Code 7322 510 7322 535 Personal injury can result from contact with refrig erant 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 precaution 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 Use a certified recovery and recycling cart to
65. ine again 7 Start the engine If you cannot start the engine the engine needs more priming If the engine continues to misfire or to smoke more priming is necessary Repeat step 6 if the engine will not start Note The electric fuel priming pump will only operate if the engine start switch key is in the OFF position Shut off the engine before any additional priming 8 Run the engine at the LOW IDLE position until the engine runs smoothly Note Do not activate the priming pump while you crank the engine Refer to Operation and Maintenance Manual Fuel System Secondary Filter Replace for information on replacing the filter 101969411 Fuel System Primary Filter Clean Replace SMCS Code 1260 070 1260 510 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 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 t
66. information Illustration 286 g01076258 2 On the right side of the machine remove hydraulic oil filler cap 1 in order to relieve the tank pressure Remove the filler strainer 3 Remove four bolts 2 in order to remove the cover from the case drain filter 180 Maintenance Section Hydraulic System Oil Level Check SEBU7763 03 4 Remove case drain filter 3 and properly discard the case drain filter 5 Clean the strainer the filter housing and the oil filler cap in a clean nonflammable solvent 6 Install a new case drain filter 7 Install the strainer the cover and the four bolts Illustration 287 g01103238 Steering charge filter 8 Change the steering charge filter Reference See Steering Charge Filter Change in this manual for more information 9 Fill the hydraulic system with new oil See Operation and Maintenance Manual Capacities Refill Install hydraulic oil filler cap 1 10 Start the engine Illustration 288 g01022619 11 Maintain the oil level to the FULL mark in the sight gauge for the hydraulic oil tank Check with the attachments on the ground and cold oil Add oil if necessary 12 Stop the engine 13 Close the access door For additional information about hydraulic system oil see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 101969751 Hydraulic Sy
67. iscard the fuel filter properly 4 Clean the filter base Make sure that all of the old seal is removed 5 Install the Fuel Filter Coat the seal of the new filter with clean diesel fuel 6 Install the new filter by hand When the seal contacts the base tighten the filter according to the instructions on the filter Rotation index marks are positioned on the filter at 90 degree intervals Use these rotation index marks as a guide when you tighten the filter 7 Turn lever 1 in order to resume fuel supply 8 Prime the fuel system See the Topic Fuel System Prime in this manual 9 Close the engine access door 101969542 Fuel Tank Cap Filter and Strainer Replace Clean SMCS Code 1273 070 STR 1273 070 Z2 1 fl NUE 2 om TILA 3 g01022482 Illustration 270 The fuel tank is located on the rear of the machine The filler cap 1 is on the left side of the machine next to the ROPS Only vented fuel caps have filters Machines without the fast fill fuel adapter require a vented fuel cap il TXTTOO 02 CAT E 5 TE a SAVA JA j Illustration 271 g01110732 1 Lift lever 5 in order to remove the fuel tank filler cap Turn the lever counterclockwise until the lever stops Lift the cap straight up in order to remove the cap 2 Remove the fuel strainer from the filler neck 3 In order to replace the filter assembly remove two screws that secure filter assemb
68. l Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Open the engine access door on the left side of the machine Illustration 238 g01025579 If the machine is equipped with a high speed oil change use a 126 7539 Nozzle g00490801 Illustration 239 1 Remove two bolts in order to remove the crankcase drain access cover which is in the crankcase guard 158 Maintenance Section Engine Oil and Filter Change SEBU7763 03 Illustration 240 g00670611 2 Remove the 4P 0520 Plug Adapter from the drain valve if equipped 3 Install a 25 4 mm 1 00 inch pipe into the drain valve The pipe requires a 1 11 1 2 NPTF pipe thread 4 Open the drain valve Allow the oil to drain into a suitable container A drain hose may be attached to the pipe to aid in draining 5 When the oil has completed draining from the crankcase close the drain valve Remove the pipe Install the 4P 0520 Plug Adapter Install the access cover Illustration 241 g01025590 6 Remove engine oil filter element 1 and discard the engine oil filter element properly Make sure that all of the old filter seal is removed from the filter base 7 Apply a thin coat of oil to the seal on the new filter 8 Install the new engine oil filter e
69. l System Prime SMCS Code 1250 548 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 Electric Fuel Priming Pump NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately The electric fuel priming pump is located in the engine compartment on the left side of the machine 1 Turn the ignition switch to the OFF position Num A p RSQ Illustration 263 g01124784 2 Twist valve 1 in order to open the air purge valve 3 Hold the switch for the electric fuel priming pump 2 in order to be in the ON position Allow the fuel priming pump to run until fuel without air flows through the air purge valve 1 4 Release the switch for the fuel priming pump in order to be in the OFF position Note This process will prime the fuel system regardless of the location of the air in the lines 5 Twist valve 1 in order to close the air purge valve 6 Hold the switch for the electric fuel priming pump 2 in order to be in the ON position for 20 seconds This will allow the air to be completely removed from the system SEBU7763 03 169 Maintenance Section Fuel System Primary Filter Clean Replace NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the eng
70. lement by hand Instructions for the installation of the filters are printed on the side of each Caterpillar spin on filter For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter 9 Remove oil filler cap 3 Fill the crankcase with new oil See the topic Operation and Maintenance Manual Capacities Refill in this manual Clean oil filler cap 3 and install the oil filler cap 10 To ensure that the correct amount of oil was added always measure the oil level with the dipstick 2 CADD FULL ENGINE STOPPED Illustration 242 g00489188 11 Check the ENGINE STOPPED side of the dipstick while the engine is stopped The oil should be cold Maintain the oil level between the LOW mark and the FULL mark This method should be used as reference only before the engine is started 2 ADD FULL LOW IDLE Illustration 243 g00489186 12 Check the LOW IDLE side of the dipstick while the engine is running The oil should be at operating temperature Maintain the oil level between the ADD mark and the FULL mark This is the only accurate way to check the oil level 13 Install the access cover for the crankcase drain For additional information about oil types see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer SEBU7763 03 1
71. lt in injury or death as any Warning Category 3 notifications will not be relayed to the operator Check the operation of the 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 self testing feature verifies that the display module is properly operating The internal circuits the indicators and the gauges are automatically checked Illustration 291 g01113652 Instrument module The operator must observe the indicators and the gauges in order to determine whether gauge module 1 action light 2 alert indicators 3 and the LCD display 4 are operating properly The self test lasts for approximately three seconds During the self test all status indicators on the instrument module light 182 Maintenance Section Lift Cylinder Yoke Bearings Lubricate SEBU7763 03 The digital display shows the following readouts e Initial part number of the instrument module All indicators of units Deg C kPa rpm and liters e X10 readout e Symbol for the hour meter e 8 8 8 X 8 8 readout The pointers in the quad gauge point upward Then the pointers point to the left Then the pointers point to the right Then the pointer
72. ly 4 to the fuel cap Remove filter assembly 4 valve 3 and the gaskets 4 Wash the cap and the strainer in a clean nonflammable solvent SEBU7763 03 173 Maintenance Section Fuel Tank Water and Sediment Drain 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 7 drop into the slots in the adapter Rotate lever 5 clockwise until the lever stops Lower lever 5 over locking tab 6 Fast Fill Fuel Adapter If Equipped See illustration 270 Machines that are equipped with a fast fill fuel adapter 2 have identical fuel caps as systems without a fast fill fuel adapter Use the same procedure for changing the filter in the two systems i027 70686 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S 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 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products
73. m not fol lowing the proper procedure or the recommended tooling To prevent the possibility of injury or death follow the established procedure using the recommend ed tooling NOTICE The machine must be parked on a level surface to perform this procedure Personal injury or death can occur from not fol lowing the proper procedure or the recommended tooling To prevent the possibility of injury or death follow the established procedure using the recommend ed tooling NOTICE The machine must be parked on a level surface to perform this procedure Note All the weight of the machine must be removed from the equalizer bar Equalizer bar must have free movement in order to be measured To check the equalizer bar center pin for looseness and for unusual wear perform the following steps 6 Illustration 230 g01108801 1 Clean the areas that are around the center pin and equalizer bar im t Q gt lo g o 0 A GQ LY Illustration 231 g01108803 2 Put a 55 ton hydraulic jack in position under the main frame as shown 154 Maintenance Section Engine Oil Level Check SEBU7763 03 Illustration 232 g01108804 3 Position a dial indicator on the equalizer bar and place the probe of the dial indicator under the center of the frame for the pin Set the dial indicator to zero 4 Jack up the f
74. machine 6 Reattach the electrical power to the HID lamp 7 Check the HID lamp for proper operation Note Consult your Caterpillar dealer for additional information on HID lamps 102054663 Horn Test SMCS Code 7402 081 Test the horn on a daily basis Press downward on the horn button in order to sound the horn If the horn does not sound make the necessary repairs before you operate the machine 103623772 Hydraulic System Filter Screens Clean SMCS Code 5068 The screen should be cleaned especially when one of the following situations have occurred e Failure of the Implement Pump e Failure of the Fan Pump e Failure of the Fan Motor e Cleaning of the Hydraulic Tank e PCR Engine Overhaul 1 Park the machine on a level surface Lower the work tool to the ground Engage the parking brake 2 Turn the engine start switch key to ON 3 Move the hydraulic control levers through all of the positions in order to release pressure 4 Turn the engine start switch key to OFF 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 Before removing the filler cap press the valve re lief button on the hydraulic tank in order to relieve the tank pressure 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
75. ment exceeds 2 54 mm 100 inch Consult your Caterpillar dealer for an inspection and for repair instructions Equalizer Bar End Pins Oil Level Check SMCS Code 7206 535 NOTICE Apply gear oil through the fittings with a hand oper ated lubrication pump or a suitable grease gun Use of pressure operated lubricating equipment damages the seals NOTICE Before and after the equalizer bar end pin is filled with gear oil seal 1 must be flush with the equalizer bar If the seals are not flush damage to the seals can result by overfilling Illustration 248 Illustration 249 g00586858 1 Clean the areas that are around the end pin with a high pressure wash Inspect the condition of the seal 1 2 Check the area for oil leakage Be sure that the seal is in a neutral position 3 Remove plug 2 SEBU7763 03 161 Maintenance Section Equalizer Bar End Pins Measure 4 Check the oil level Oil level 4 should be at the top of the hex head on the fitting 5 If the oil level is low apply the gear oil through fitting 3 until the gear oil reaches oil level 4 at the top of the hex head on the fitting Remove any excess oil This will maintain a volume of air The gear oil must be applied with a 7H 1680 Lubrication Pump or a suitable grease gun Use the recommended gear oils that are listed in the table for Lubricant Viscosities for Ambient
76. n excessive fuel usage and or shortened engine component life Adjust the electronic unit injector at the same interval as the valve lash adjustment Refer to your machine s Service Manual or your Caterpillar dealer for the complete adjustment procedure 103619440 Engine Air Filter Primary and or Secondary Element Clean Replace SMCS Code 1054 070 SE 1054 070 PY 1054 510 PY 1054 510 SE Primary Filter NOTICE Service the primary filter element only when the alert indicator for the intake air filter is flashing Do not open the filter compartment unless it is time for service Opening the filter compartment can cause dirt to get into the clean side of the filter housing NOTICE Extremely short air filter life can result if the preclean er system malfunctions If air filter life is drastically re duced from typical for the operating conditions con sult your Caterpillar Dealer The exhaust system dust ejector for the strata tube precleaner must pull a min imum vacuum of 508 mm 20 inch of water NOTICE Service the engine air filters with the engine stopped Engine damage could result NOTICE Always leave the secondary filter element in place while you clean the primary element or while you clean the air cleaner housing NOTICE Do not use the filter for longer than one year 1 Open the engine compartment s access door if equipped Illustration 222 g00470852 150 Maintenanc
77. n the transmission 5 Install the bottom guard Reference See Operation and Maintenance Manual Transmission System Oil and Screens Change Clean in order to fill with oil 186 Maintenance Section Power Train System Oil And Screens Change Clean SEBU7763 03 103644987 Power Train System Oil And Screens Change Clean SMCS Code 3067 070 3067 510 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 Remove the filler cap slowly 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 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 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Drain the Oil and Change the Transmission Oil Filter Elements Operate the machine in order to warm the power train oil The machine must be level Lower the attachments with sligh
78. ne the amount of hydraulic oil that is needed to fill the hydraulic oil tank 13 Inspect the filler cap gasket Replace the gasket if damage or wear is evident 14 Install the filler cap 15 Start the engine Run the engine for a few minutes 178 Maintenance Section Hydraulic System Oil Filter Pilot Replace SEBU7763 03 Illustration 281 g01022619 The arrow indicates the FULL mark Enlarged view of the sight gauge 16 Maintain the oil level to the FULL mark in the sight gauge Check with the attachments on the ground and with cold oil Add oil if necessary 17 Stop the engine For additional information about hydraulic system oil see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 102214240 Hydraulic System Oil Filter Pilot Replace SMCS Code 5068 510 PS 5068 510 5092 510 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 Remove the filler cap slowly in order to relieve pressure Pilot Hydraulic Oil Filter 1 Lower the bulldozer and the ripper to the ground Turn off the engine Illustration 282 g01075799 2 The hydraulic tank is located on
79. ngine Run the engine at low idle Illustration 245 g00038585 2 Watch the top surface of each valve rotator Whenever an inlet valve closes or an exhaust valve closes each valve rotator should turn 3 If a valve rotator fails to rotate consult your Caterpillar dealer for service Note 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 Note If a damaged valve rotator is not replaced some valve face guttering could result Metal particles from the valve could fall into the cylinder This could cause damage to the piston head and to the cylinder head 160 Maintenance Section Equalizer Bar Center Pin Measure SEBU7763 03 102092065 Equalizer Bar Center Pin Measure SMCS Code 7206 040 PN 7206 082 7207 086 PN Illustration 246 g01066674 Rear view To check the equalizer bar center pin for looseness and for unusual wear perform the following steps Note All the weight of the machine must be removed from the equalizer bar Equalizer bar must have free movement in order to be measured 1 Clean the areas that are around the center pin with a high pressure wash g00736127 Illustration 247 Front view 2 Install a dial indicator and measure the vertical play in the center pin joint Note Schedule the center pin joint for repair if move
80. nk access cover 6 13 Assemble the drain lines 14 Fill the hydraulic tank Reference For the correct procedure refer to Operation and Maintenance Manual Hydraulic System Oil Change 15 Replace filler cap 1 102229763 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 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 Remove the filler cap slowly to relieve pressure SEBU7763 03 177 Maintenance Section Hydraulic System Oil Change 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 Operate the machine in order to warm the oil Park the machine on level ground Lower the bulldozer blade and the ripper to the ground and apply slight downward pressure Engage th
81. nozzle from the access slot Close the access cover 10 Repeat Steps 5 through 9 from the left side of the machine in order to clean the cores on the right side of the machine 11 Use a regular air nozzle in order to blow off the cores from the rear and clean the entire engine compartment 12 Close both of the engine access doors 13 Restart the engine Operate the fan in the forward direction continuously for 2 minutes 14 Reverse the air flow Operate the fan in the reverse mode continuously for 2 minutes 15 Return to operating the machine in work mode Note Adjust the frequency of cleaning according to the effects of the operating environment Modify the typical cleaning procedure above for optimal results as needed 103571752 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 Level 2 Analysis NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers 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 op
82. nsion between the height of the front idler tread and the height of the roller tread The following check is for undercarriage systems with either design of idler 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 25 mm 1 inch to 37 mm 1 5 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 added under the bogie pads in order to raise the front idler Also the adding of shims under the bogie pads lower the rollers If the machine is operated in SOFT UNDERFOOT conditions shims can be removed under the bogie pads in order to raise the rollers Also the removal of shims under the bogie pads lowers the idlers Lowering the front idler can improve dozing performance If ground rippling by the dozer or excess vibration occur in soft material shims can be installed in order to raise the front idler Consult your Caterpillar dealer for detailed information about checking the idler and about adjustments to the idler 102229667 Fue
83. ntenance Section Cooling System Coolant Extender ELC Add 103396142 Cooling System Coolant Extender ELC Add SMCS Code 1352 538 1395 538 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 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Table 20 Cat ELC Extender and the Cooling System Capacity Recommended Amount of Cat ELC Extender 2 15 L 72 oz Cooling System Capacity 84 L to 114 L 22 to 30 US gal When a Caterpillar Extended Life Coolant ELC is used an extender must be added to the cooling system See the Operation and Maintenance Manual Maintenance Interval Schedule for the proper service interval The amount of extender is determined by the cooling system capacity For additional information about adding an extender see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer Extended Life Coolant ELC Extender Use a 8T 5296 Coolant Conditioner Test
84. ny 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 S O S oil analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent oil samplings that are evenly spaced If the machine is operated under a high load and or under high temperature conditions sample all fluids at the 250 hour interval 1 Run the machine until operating temperature has been reached The sample must be at operating temperature in order to take an accurate sample 164 Maintenance Section Final Drive Seal Guard Packing Replace SEBU7763 03 Illustration 255 g01117789 2 Remove the cover plate 3 Obtain an oil sample The use of a sampling gun that is inserted into the sump is the preferred method for obtaining a sample Note Do not use the drain stream method to obtain a sample of the final drive oil A stream of dirty oil from the bottom of the compartment will contaminate the sample Likewise never dip an oil sample from an oil container or pour a sample
85. ollowing topics in this publication e Cooling System Specifications e Capacities Refill Note Caterpillar antifreeze contains additives 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 9 Start the engine Run the engine without the filler cap until the thermostat opens and the coolant level stabilizes 10 Look into filler tube 1 Maintain coolant level between area 2 and area 3 of the filler tube Adding coolant above this area of the filler tube will cause the coolant to overflow the cooling system 11 If the gasket is damaged replace the filler cap Install the filler cap 12 Stop the engine QOO Illustration 213 g00475722 Illustration 214 g01117259 13 Clean the radiator cores with compressed air You may need to use water in order to remove debris 14 Allow the radiator cores to dry completely before operating the machine in the work mode Reference See Operation and Maintenance Manual Cooler Cores and A C Condenser Clean for information on a typical cleaning procedure For additional information about the cooling system coolant see Operation and Maintenance Manual SEBU6250 Caterpillar Machine Fluids Recommendations Cat Extended Life Coolant ELC or consult your Caterpillar dealer SEBU7763 03 145 Mai
86. on Make sure that the installation tool does not damage the filter 7 Install the access cover 8 Start the engine Illustration 285 g01022619 9 Maintain the hydraulic oil to the FULL mark in the sight gauge that is on the outside of the hydraulic tank 10 Install hydraulic tank filler cap 2 11 Install access cover 3 12 Stop the engine For additional information about hydraulic systems refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 102769408 Hydraulic System Oil Filters Replace SMCS Code 5068 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 disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Lower the bulldozer and the ripper to the ground Turn off the engine Reference See Operation and Maintenance Manual Stopping the Machine for additional
87. ools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not fill fuel filter with fuel before installing the fuel filter Contaminated fuel causes accelerated wear to fuel system parts 1 Turn the red lever 1 in order to shut off fuel supply wD A Q O Q o 3 1 Q m Q a Illustration 264 g01113804 2 Open the engine access door on the left side of the machine Illustration 265 g01022363 170 Maintenance Section Fuel System Primary Filter Water Separator Drain SEBU7763 03 3 Drain water separator bowl 3 into a suitable container and remove the bowl from the bottom of the filter element Clean the water separator bowl and inspect the seal If the seal is worn or damaged install a new seal 4 Remove filter element 2 Properly discard the filter element 5 Clean the filter base Be sure that all of the old seal is removed 6 Coat the seal of the new filter element with clean diesel fuel 7 Install the new filter element hand tight until the seal of the filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the filter use the rot
88. or if equipped 101959689 Final Drive Oil Change SMCS Code 4050 044 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 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 Illustration 253 g01018450 1 Position one final drive so that oil level mark 1 is horizontal The drain plug 3 will point downward 2 Remove oil filler plug 2 3 Remove drain plug 3 Allow the oil to drain into a suitable container SEBU7763 03 163 Maintenance Section Final Drive Oil Level Check 4 Inspect the drain plug seal Replace the drain plug seal if the drain plug seal is damaged 5 Clean the drain plug and install the drain plug 6 Fill the final drive with oil to the bottom of the filler plug opening See Operation and Maintenance Manual Capacities Refill 7 Inspect the condition of the seal of the filler plug Replace the plug seal if the plug
89. order to establish a pertinent history of data perform consistent oil samplings that are evenly spaced Illustration 312 g01019134 1 Open the access door on the right side of the cab 190 Maintenance Section Radiator Guard Pin Joint Inspect SEBU7763 03 Illustration 313 g01018659 Some components are removed for clarity 2 Remove the protective cap from the sampling port 3 Obtain a sample of transmission oil Refer to Special Publication SEBU6250 S O S Oil Analysis for information that pertains to obtaining a sample of the transmission oil 4 After you take a sample remove the cap with the tube and the probe from the bottle Discard the cap with the tube and the probe Install the sealing cap that is provided with 169 8373 Fluid Sampling Bottle 5 Replace the protective cap 6 Close the access door and secure the door For additional information about transmission system oil see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 101107744 Radiator Guard Pin Joint Inspect SMCS Code 7155 040 1 Park on a level surface 2 Raise the bulldozer blade g00584863 Illustration 314 3 Install the magnetic base of a dial indicator on the main frame of the machine Place the tip of the indicator on the bottom edge of the radiator guard directly ben
90. ound the covers and around the hoses Repair any oil leaks 102773475 Winch Oil and Breather Change Clean SMCS Code 5163 044 If equipped Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin g01076796 Illustration 340 1 Remove oil filler plug 1 2 Remove drain plug 3 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 4 Clean drain plug 3 and install the drain plug 5 Remove oil level plug 2 6 Fill the oil compartment until oil is visible at the bottom of the opening for oil level plug 2 See Operation and Maintenance Manual Capacities Refill 7 Clean the vent plug that is in filler plug 1 Use a clean nonflammable solvent 8 Install oil filler plug 1 9 Run the engine at low idle Maintain the oil level so that the oil level is visible at the bottom of the opening for oil level plug 2 10 Install the oil level plug SEBU7763 03 201 Maintenance Section Winch Wire Rope Install Winch Wire Rope Install If Equipped 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 PA140VS The cable is attached to the drum on the winch with a cable ferr
91. place 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 eon Ns ee Nes Illustration 321 g01019290 Front view Inspect both sides of 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 ROPS bolts to a torque of 1400 200 N m 1030 150 lb ft Note Apply oil to all bolt threads for the ROPS before you install the ROPS bolts Do not weld reinforcement plates to the ROPS in order to straighten the ROPS Do no
92. r for more information if this product will experience abnormally harsh operating cycles or harsh environments Table 21 D8T Series Engine Oil Change Interval Operating Conditions Normal Severe Multi d A Fuel Altitude ail High Sulfur above road from 1830 m Factor l 9 3 6000 ft to 0 5 Cat DEO soohr 500hr 500hr 250 hro Preferred ECF 1 10 0 minimum 500 hr 500 hr 500 hr 250 hr TBNG Preferred ECF 1 250 TBN 500 hr 500 hr hr 250 hr below 10 0 250 API CG 4 500 hr 250 hr hr 250 hr 1 The standard oil change interval for the D8T is every 500 hours If the operating conditions fuel rates and recommended oil types for your engine are listed in the table21 are met The traditional oil change interval for engines is 250 hours The standard oil change interval in this machine is 500 hours if the operating conditions and recommended oil types that are listed in this table are met Improvements in the engine allow this engine oil change interval This new standard interval is not permitted for other machines Refer to the applicable Operation and Maintenance Manuals for the other machines 2 Normal conditions include these factors Fuel sulfur below 0 5 altitude below 1830 m 6000 ft and good air filter and fuel filter maintenance Normal conditions do not include high load factor harsh operating cycles or harsh environments 3 Load factors are
93. reen 2 in the torque converter housing Install the bolts and drain valve body 1 6 Install the bottom guard Reference See Operation and Maintenance Manual Transmission System Oil and Screens Change Clean in order to fill with oil 102877237 Track Check Adjust SMCS Code 4170 036 Illustration 326 g01015715 Check the track adjustment Check the track for wear and for excessive dirt buildup 196 Maintenance Section Track Check Adjust SEBU7763 03 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 1 Move the machine forward Allow the machine to coast to a stop without the use of the service brakes Adjust the tracks while you are in the machine s typical operating conditions If packing conditions prevail on the workplace the tracks should be adjusted without removing the packed material 2 To measure the sag in the track stretch a string over the grousers that are between the sprocket and the front idler Take the measurement from the string to the top of the grouser at the maximum measurement Dimension A is the maximum distance between the string and the grouser Illustration 327 g01109482
94. ris has hardened in the center of the cores these cores may need to be removed from the machine for thorough cleaning If steam or water pressure is used to clean the cores make sure that the pressure is controlled in order to prevent the fins from bending If you use a degreaser or special cleaning agents wash the core with detergent and hot water Thoroughly rinse the core with clean water Dry the cores completely before operating the machine in the work mode Dry If steam or water is used to clean the cores make sure that the cores are completely dry before the track type tractor is put back to work Use compressed air to blow dry the wet cores the engine engine access doors and the hood Close both engine access doors If the machine is in a clean environment start the engine and allow the fan to run continuously in the reverse mode until the cooling system has completely dried Allow the machine to sit overnight before operating the machine in the work mode Typical Cleaning Procedure That Uses Compressed Air The wood chip and waste handling arrangements have special cleaning features e continuous reverse fan function e 307 6728 Air Nozzle in access slots in the radiator guard These tools can be used to develop a cleaning procedure that best suits your application One possible sequence for cleaning is outlined below Illustration 209 g01385729 1 At the proper cle
95. ront of the machine until the weight of the roller frames are supported by the equalizer bar 5 Take a reading of the dial indicator in order to determine the amount of wear on the pin and bearing Note Schedule the center pin joint for repair if movement exceeds 2 54 mm 100 inch Consult your Caterpillar dealer for an inspection and for repair instructions Equalizer Bar Pads Illustration 233 g01108806 The equalizer bar pads are under the front guard which is underneath the machine Inspect the equalizer bar pads for cracked rubber and for missing portions of rubber Consult your Caterpillar dealer for replacement parts and for replacement instructions 101959267 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 Open the engine access door if equipped on the left side of the machine Illustration 234 g01025526 cADD FULL LOW IDLE g00489186 Illustration 235 CADD FULL ENGINE STOPPED Illustration 236 g00489188 2 Check the LOW IDLE side of dipstick 1 while the engine is running The oil should be at operating temperature Maintain the oil level between the ADD mark and
96. rotation 2 Open the cover to the access slot 2 on the right side of the radiator guard 3 Insert the air nozzle into the slot 4 Turn on the air supply 5 Move the air nozzle in a sufficient pattern to clean debris from the cooling system which includes the radiator cores a Turn off the air supply when the nozzle cleaning is completed 6 Remove the air nozzle from the slot Close the access cover 148 Maintenance Section Cooling System Water Temperature Regulator Replace SEBU7763 03 After cleaning start the engine and accelerate the engine to high idle rpm This will help in the removal of debris and drying of the core if necessary Stop the engine Inspect the core for cleanliness Repeat the cleaning if necessary Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 NOTICE Failure to replace the engine s thermostat on a regu larly scheduled basis could cause severe engine dam age NOTICE 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 Since Caterpillar engines incorporate a shunt design cooling system it is mandatory to alw
97. rs 4 Install the recirculation filter element Make sure that the filter element is centered If the filter is not centered the system will not function properly Note Clean the filters more often in dusty conditions 138 Maintenance Section Cooler Cores and A C Condenser Clean SEBU7763 03 103400783 Cooler Cores and A C Condenser Clean SMCS Code 1064 070 1353 070 1374 070 7320 070 Cooler Cores The following cooler cores are cooled by the hydraulic fan that is located in the radiator guard at the front of the track type tractor Aftercooler core The aftercooler core cools the inlet manifold air to the engine Hydraulic oil cooler core The hydraulic oil cooler core cools hydraulic oil Radiator core The AMOCS radiator cores cool the engine coolant A C Condenser Core The air conditioning condenser core cools the refrigerant in the air conditioning system Illustration 201 991989124 Air conditioner condenser behind the aftercooler 2 Aftercooler core 3 Hydraulic oil cooler core 4 Radiator cores AMOCS 5 A C condenser core Aftercooler Core l o D z int R lo SAG Ta e LA Illustration 202 g01953704 Rear view of aftercooler Radiator Core Illustra
98. s point to the final position e The readout of the gear shows e The speed readout shows 888 MPH and km h e The rear action light ON then OFF e The forward action light stays illuminated e The 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 Stop the engine Make any necessary repairs before you operate the machine 101959914 Lift Cylinder Yoke Bearings Lubricate SMCS Code 5102 086 BD Illustration 292 g01018514 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 two fittings Use MPGM Grease 102106227 Oil Filter Inspect SMCS Code 1318 507 3067 507 5068 507 Inspect a Used Filter for Debris Illustration 293 g00100013 The element is shown with debris Use a filter cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can indicate a possible failure SEBU7763 03 183 Mainten
99. 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 Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts Before you replace the secondary fuel filter element replace the primary fuel filter element See the Topic Fuel System Primary Filter Replace in this manual wD a Q O Q o 3 1 Q SSN Q a Illustration 268 g01113804 1 Turn the red lever 1 in order to shut off fuel supply 2 Open the engine access door on the left side of the machine 172 Maintenance Section Fuel Tank Cap Filter and Strainer Replace Clean SEBU7763 03 Illustration 269 g01022384 3 Remove the secondary fuel filter 2 D
100. spose of all fluids according to local regulations and mandates SEBU7763 03 195 Maintenance Section Torque Converter Scavenge Screen Clean g01103238 Illustration 324 1 Open the access door on the right side of the cab 2 Remove the steering charge filter Discard the used filter element properly Make sure that all of the old filter seal is removed from the filter base 3 Clean the filter base with a clean cloth 4 Install the new filter element by hand Instructions for the installation of the filters are printed on the side of each Caterpillar spin on filter For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter 102777193 Torque Converter Scavenge Screen Clean SMCS Code 3101 070 MGS 3105 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin When you change the transmission oil clean the torque converter scavenge screen 1 Remove the bottom guard in order to gain access to the torque converter Note Drain all fluids into a suitable container A dC Ss Illustration 325 g01387611 2 Remove the bolts and drain valve body 1 from the torque converter as shown 3 Remove torque converter scavenge screen 2 from the torque converter housing 4 Wash the screen in a clean nonflammable solvent 5 Install torque converter scavenge sc
101. ssembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component Illustration 266 g01022350 SEBU7763 03 171 Maintenance Section Fuel System Secondary Filter Replace ee o l Illustration 267 1 Element 2 Bowl 3 Drain g00104007 Bowl 2 should be monitored daily for signs of water If water is present drain the water from the bowl 1 Open drain 3 The drain is a self ventilated drain Catch the draining water in a suitable container Dispose of the water properly 2 Close drain 3 NOTICE The water separator is under suction during normal engine operation Ensure that the drain valve is tight ened securely to help prevent air from entering the fuel system i01969432 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE 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
102. stem 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 Remove the filler cap slowly in order to relieve pressure Lower the bulldozer and the ripper to the ground Place the ripper shanks in the vertical position The hydraulic tank is on the right rear side of the machine Illustration 289 g01022619 1 Maintain the oil level to the FULL mark in the sight gauge Check the oil level when the oil is cold Verify that the oil level is below the FULL mark before you remove the filler cap 2 If the hydraulic system requires additional hydraulic oil remove the filler cap slowly in order to relieve the pressure Add oil through the filler tube 3 Clean the filler cap and install the filler cap SEBU7763 03 181 Maintenance Section Hydraulic System Oil Sample Obtain 101960922 Hydraulic System Oil Sample Obtain SMCS Code 5095 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 pr
103. t down pressure See the Operation and Maintenance Manual Transmission and Torque Converter Oil Filters Replace in this manual for the procedure to change the filters Illustration 301 g01118275 Open the left engine compartment in order to locate the high speed oil change arrangement Use a 126 7538 Nozzle if the machine is equipped with the high speed oil change arrangement This arrangement removes oil from the sump in the bevel gear case The high speed oil change does not remove oil from the torque converter or from the transmission case g00484767 Illustration 302 1 Remove the plug from the drain in the bevel gear case Install a 4C 8563 Swivel into the valve Clamp a hose to the swivel A 25 4 mm 1 inch pipe and hose can be used Use a 25 4 mm 1 inch pipe with 1 11 1 2 NPTF threads Do not tighten the pipe 2 Turn the swivel or pipe clockwise in order to open the internal drain valve Allow the oil to drain into a suitable container 3 Remove the rear bottom guard SEBU7763 03 187 Maintenance Section Power Train System Oil And Screens Change Clean g00484821 Illustration 303 4 Remove plug 2 from the drain valve in the torque converter Install a 12 7 mm 5 inch pipe into the drain valve Use a 12 7 mm 0 50 inch pipe with 1 2 14 NPTF threads 5 Clamp a hose to the pipe in order to drain the oil into a suitable container 6 Open drain valve 1 and dr
104. t 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 102429589 Seat Belt Inspect SMCS Code 7327 040 7520 Always check the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine Replace any parts that are damaged or worn before you operate the machine 194 Maintenance Section Seat Belt Replace SEBU7763 03 Illustration 322 g00932801 Typical example Check the seat belt mounting hardware 1 for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight Check buckle 2 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect the seat belt 3 for webbing that is worn or frayed Replace the seat belt if the seat belt is worn or frayed Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware Note Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor If your machine is equipped with a seat belt extension also perform this
105. the FULL mark This is the only accurate way to check the oil level SEBU7763 03 155 Maintenance Section Engine Oil Sample Obtain Check the ENGINE STOPPED side of the dipstick while the engine is stopped The oil should be cold Maintain the oil level between the LOW mark and the FULL mark This method should be used as reference only before the engine is started Note When you operate the machine on severe slopes the oil level in the engine crankcase must be at the FULL mark on the LOW IDLE side of dipstick 1 3 Remove oil filler cap 2 and add oil if necessary 4 Clean the oil filler cap and install the oil filler cap 5 Close the engine access door if equipped Engine Oil Sample Obtain SMCS Code 1348 554 SM 1348 7542 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 Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates
106. the right side of the machine Depress the button on breaker relief valve 1 next to the filler cap 2 in order to relieve any tank pressure Remove the filler cap Illustration 283 g01117647 3 Remove access cover 3 at the rear of the fuel tank g01117748 Illustration 284 Rear view 4 Remove spin on type filter 4 that is the pilot hydraulic oil filter The pilot hydraulic oil filter is attached below the accumulator manifold Properly discard the filter element SEBU7763 03 179 Maintenance Section Hydraulic System Oil Filters Replace 5 Apply a thin coat of oil to seal on the new filter Install a new pilot hydraulic oil filter hand tight until the seal of the pilot hydraulic oil filter contacts the base Note the position of the index marks on the filter in relation to a fixed point on the filter base Note There are rotation index marks on the pilot hydraulic oil filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the pilot hydraulic oil filter use the rotation index marks as a guide 6 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide For non Caterpillar filters use the instructions that are provided with the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installati
107. tion 203 g01307600 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 SEBU7763 03 139 Maintenance Section Cooler Cores and A C Condenser Clean A C Condenser Core ol i l o o a E o Illustration 204 g01060198 A common arrangement for the air conditioner condenser is located behind the radiator Illustration 205 901224494 Another arrangement for the air conditioner condenser is located under the hood Remote A C Condenser Core In some machine arrangements the a c condenser core is remotely located A remote mounted a c condenser core is cooled by fans with electric drive Illustration 206 g01117118 Air conditioner condenser on the right side of the machine Illustration 207 g01117129 Air conditioner condenser on the top of the machine Inspect Note Adjust the frequency of inspection according to the effects of the operating environment Illustration 208 g01385726 Turn off the engine Open both of engine access doors 1 Inspect the cooling system for the following conditions coolant leaks oil leaks damaged fins and tubes Inspect the following par
108. tions and mandates 146 Maintenance Section Cooling System Coolant Level Check SEBU7763 03 3 Add 2 15 L 72 oz of Extender to the cooling system 4 Start the engine Run the engine without the filler cap until the thermostat opens and the coolant level stabilizes Check for leaks me Illustration 216 g00475722 5 Look into filler tube 1 If necessary add premixed coolant in order to correct the coolant level Maintain the coolant level between area 2 and area 3 of the filler tube Adding coolant above this area of the filler tube will cause the coolant to overflow the cooling system 6 Replace the radiator cap if the cap gasket is damaged Install the radiator cap 103396143 Cooling System Coolant 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 radiator has a surge tank There is no top tank in this cooling system The surge tank has a filler cap and a sight glass It is not necessary to remove the filler cap in order to check the coolant level The sight glass is inside
109. ts of the cooling systems air lines connections and clamps for damage Make repairs for damage if necessary 140 Maintenance Section Cooler Cores and A C Condenser Clean SEBU7763 03 Note If parts of the aftercooler system may appear to be damaged or if parts of the aftercooler system are repaired a leak test is highly recommended Refer to Special Instruction SEHS8622 Using the FT1984 Air to Air Aftercooler Leak Test Group The FT 1984 Aftercooler Testing Group can be used for aftercoolers that have hoses with an inside diameter of 102 mm 4 00 inches or 114 mm 4 50 inches For more detailed information on testing and inspection see Special Publication SEBD0518 Know Your Cooling System Clean 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 Radiator cores aftercooler cores hydraulic oil cooler cores and a c condenser cores needed to be cleaned regularly Adjust the frequency of cleaning according to the effects of the operating environment Blow out the cores with compressed air Move the air nozzle in a systematic pattern so that the air flow covers the whole core that includes areas in the corner Clean the middle space between the aftercooler core
110. ule The ferrule is placed into a socket on the drum Use the following table to order the cable Table 25 Wire Cable Wire Rope Recommended Holding Capacity Diameter Ferrule 25 mm 1 inch L 8 91 m 300 ft 29 mm J 9 84 m 276 ft 1 13 inch 32 mm J 10 59 m 193 ft 1 25 inch Illustration 341 g01076208 1 Put the cable in a straight line behind the tractor 2 Install the ferrule end into the socket 3 Reel in the cable 101961420 Window Washer Reservoir Fill If Equipped SMCS Code 7306 544 NOTICE When operating in freezing temperatures use Caterpillar or any commercially available nonfreezing window washer solvent a a lt 5 J g01018997 Illustration 342 ee Windshield Washer The washer fluid bottle is on the left side of the cab on the front post as shown Open the access cover Remove the fluid bottle cap in order to fill the washer fluid bottle 202 Maintenance Section Window Wipers Inspect Replace SEBU7763 03 Window Wipers Inspect Replace If Equipped SMCS Code 7305 040 7305 510 Illustration 343 g01018994 Inspect the front windshield wiper blade the right windshield wiper blade the left windshield wiper blade and the rear windshield wiper blade Replace any wiper blades that are damaged or worn Replace any wiper blades that streak the windshield 101083628 Windows Cl
111. ult your Caterpillar dealer 4 Replace the protective cap Close the left side engine compartment Submit the sample for Level 2 analysis 103398001 Cooling System Coolant ELC Change SMCS Code 1395 044 For information about adding an extender to your cooling system see the Topic Cooling System Coolant Extender ELC Add in this manual or consult your Caterpillar dealer 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 To Drain the Cooling System The filler cap is located inside the access door on the top of the radiator guard Illustration 211 g01113455 Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand Cooling System Conditioner contains alkali Avoid contact with skin and eyes 1 Slowly loosen filler cap 1 in order to relieve system pressure Remove the filler cap 2 Remo
112. ve right access cover 2 and left access cover 3 for the coolant drain One cover is located on the front right side of the machine bottom guard The other cover is on the left side of the machine bottom guard Illustration 212 g01017961 3 Direct the drain hoses into suitable containers 144 Maintenance Section Cooling System Coolant ELC Change SEBU7763 03 4 Open the drain valve Allow the coolant to drain into a suitable container 5 Flush the system with water Flush the system until the draining water is clear Note If the cooling system is already using ELC cleaning agents are not required to be used at the specified coolant change interval Cleaning agents are only required if the system has been contaminated by the addition of some other type of coolant or by cooling system damage Clean water is the only cleaning agent that is required when ELC is drained from the cooling system Note 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 Refer to the Topic Cat Extended Life Coolant ELC in Operation and Maintenance Manual SEBU6250 6 Close the drain valves and install the plug 7 Replace the access covers 8 Add the ELC solution See the f
113. will need to be done at least daily Cleaning may be needed on a more frequent basis The clean out schedule must be followed even when ambient temperatures are low This will prevent debris accumulation in the cores and future plugging Access to the cores is through the engine access doors from the rear of the cores which results in blowing air in the same direction as the normal air flow through the fan The wood chip and Waste Handling arrangements offer two options for blowing air in the opposite direction of normal fan air flow First the reverse fan function has a continuous reverse mode This allows prolonged periods of the reverse flow while the machine is parked Next slots are provided in both sides of the radiator guard for use with a 307 6728 Air Nozzle which concentrates air flow backward through the cores Blow out the cores with compressed air Move the air nozzle in a systematic pattern so that the air flow covers the whole core that includes the areas in the corners Do not use steam or high pressure water for cleaning frequently If steam or high pressure water is required to dislodge any debris that is held deep in the cores make sure that the cleaning is thorough This may require opening radiator doors and removing debris guards for access Incomplete cleaning with water may cause remaining debris to harden in place Use lights and wire probes in order to ensure that the cleaning is thorough and complete If the deb

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