Home

Maintenance Intervals - Safety

1. l Illustration 306 4 Left hand cab entry door reference only 5 Steering charge filter element g02501916 2 Locate steering charge filter element 5 The filter is inside the enclosed compartment forward and below the fuel tank fill cap on the left hand side of the machine above the fender 3 Remove the filter element Discard the used filter element properly Make sure that all of the old filter seal is removed from the filter base 4 Clean the filter base with a clean cloth 5 Apply a thin coat of oil to the seal on the new filter Install the new filter element by hand SEBU8593 197 Maintenance Section Torque Converter Scavenge Screen Clean Instructions for the installation of the filter are printed on the side of each Caterpillar spin on filter For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter 103967449 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 After a major power train component failure 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 m LLLLLLLL Lt IITA 4 UT Illustration 307 g01387611 2
2. ej 0 4 g01152685 Illustration 304 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 Cat 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 104346782 Steering Charge Filter Replace SMCS Code 431F 510 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 opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Illustration 305 g02501857 Hydraulic oil tank located above right hand fender 1 Hydraulic tank filler cap 2 Pressure relief check valve 3 Oil level sight gauge 1 Remove any built up pressure in the hydraulic tank Depress check valve 2 on top of the tank N e BAN _ J CY
3. Illustration 183 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 104316512 Cab Filter Fresh Air Clean Inspect Replace SMCS Code 7342 040 7342 070 7342 510 Cab Filter Fresh Air Clean Inspect Replace led g02476319 Illustration 184 Cab Fresh Air Filter Assembly Illustration 185 g02476391 Expanded View of Filter Assembly Components Note Use three points of contact when you access the cab filter fresh air Reference See Operation and Maintenance Manual Mounting and Dismounting for more information This filter assembly is located outside of the left hand cab window 1 The filter cover 1 is located at the front end of the filter assembly Release three clamps 2 and remove the filter cover 2 Remove filter element 3 140 Maintenance Section Cab Filter Recirculation Clean Inspect Replace SEBU8593 Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressurized air wear a protective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kP
4. Illustration 210 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 Illustration 211 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 154 Maintenance Section Engine Mounts and Equalizer Bar Inspect SEBU8593 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 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 to perfo
5. 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 filters 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 5 Install the filter cover and secure with the fastener Note Clean the filters more often in dusty conditions i03680600 Camera Clean Adjust WAVS If Equipped SMCS Code 7348 In order to maintain sufficient vision keep the Work Area Vision System WAVS camera lens and the display clean _ eee ELES TGSGSOTG Illustration 187 g01223034 The WAVS display is located in the operator station SEBU8593 141 Maintenance Section Cooler Cores and A C Condenser Clean Use a soft damp cloth in order to clean the display The display has a soft plastic surface that can be easily damaged by an abrasive material The display is not sealed Do not immerse the display with liquid Illustration 188 g01223051 A WAVS camera is located on the rear of the machine mounted on top of the ROPS or mounted on the fuel tank Use a damp cloth or water spray in order to clean the camera lens The camera is a sealed unit The camera is not affected by high pressure spray Note The camera is equipped with an internal heater to help counteract the effects of co
6. 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 spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters SEBU8593 171 Maintenance Section Fuel System Secondary Filter Replace 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 opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat 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 fle NN CNY TALS J tl ZY 2 3 g02495496 Illustration 246 1 Left
7. 104322138 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 The machine cooling system has a surge tank There is no top tank on the radiator The surge tank has a filler cap and a sight glass The removal of the filler cap is not necessary in order to check the coolant level The sight glass is inside the engine access door on the right hand side of the machine The filler cap is beneath the access cover on top of the hood forward of the engine air precleaner Illustration 198 g02478193 1 Observe 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 no coolant is present in the sight glass the coolant is low If the coolant level line is visible in the sight glass the coolant is low Add coolant in order to fill the system 2 If necessary to add coolant remove filler cap 2 slowly in order to relieve the pressure Note The factory fill is Extended Life Coolant ELC Refer to Operation and Maintenance M
8. Maintenance Manual Power Train System Oil Level Check for more information 6 Clean oil filler cap 15 Install the oil filler cap 7 Install the rear bottom guard For additional information about transmission system oil see Operation and Maintenance Manual SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 104352037 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 190 Maintenance Section Power Train System Oil Sample Obtain SEBU8593 Illustration 290 g02505876 1 Locate power train oil level gauge 5 The power train oil level gauge is located behind the angled access cover that is rearward of the left hand engine access door BRS OO HO I OT ICY SSS ke EE RERE EREE RE RERE EN EET Illustration 291 g01423532 2 Maintain the oil level within operating range X between the ADD mark and the FULL mark on the oil level gauge a When the engine is stopped and the oil is cold ambient temperature maintain the oil level on the ENGINE STOPPED COLD OIL side of the oil level gauge This method should be used as reference only before the engine is started b When the engine is running and the oil is hot operating temperature maintain the oil level on the ENGINE
9. Maintenance Section Equalizer Bar End Pins Oil Level Check SEBU8593 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 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 g00586840 Illustration 229 Illustration 230 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 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 he
10. 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 102092065 Equalizer Bar Center Pin Measure SMCS Code 7206 040 PN 7206 082 7207 086 PN g01066674 Illustration 226 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 227 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 movement exceeds 2 54 mm 100 inch Consult your Caterpillar dealer for an inspection and for repair instructions 102093902 Equalizer Bar End Pins Measure SMCS Code 7206 082 g00517058 Illustration 228 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 162
11. 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 SEBU8593 149 Maintenance Section Cutting Edges and End Bits Inspect Replace 104322329 8 Raise the bulldozer blade and remove the blocking Lower the bulldozer blade to the ground Cutting Edges and End Bits 3 Inspect Replace 9 After you operate the machine for a few hours SMCS Code 6801 040 6801 510 6804 040 6804 510 Illustration 201 g01041644 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 downward 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 bit is worn install a new end bit Note When the end bit is within 10 mm 0 4 in
12. Remove the bolts and drain valve body 7 from the torque converter as shown Remove torque converter screen 8 SEBU8593 189 Maintenance Section Power Train System Oil Level Check Suction Screen Illustration 287 g01052024 A Right side view B Front view Remove cover 9 from the main suction line that is next to the power train oil pump 10 Remove screen 11 from the main suction line Transmission Scavenge Screen Illustration 288 g01043087 Remove drain valve body 12 from the transmission Remove the transmission scavenge screen 13 Fill With Oil 1 Open access door 16 for the filler cap The filler cap is located on the left side of the machine and outside of the heater 14 above fender 18 m 1 A Till wey Illustration 289 18 g01043088 2 Remove oil fill cap 15 3 Fill the bevel gear case with oil See Operation and Maintenance Manual Capacities Refill 4 Always measure the oil with the dipstick 17 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
13. 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 result 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 180 Maintenance Section Lift Cylinder Yoke Bearings Lubricate SEBU8593 Illustration 263 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 The digital display shows the following readouts e Initial part number of the instrument module e All indi
14. gauge This procedure is the only accurate way to check the oil level Note When you operate the machine on severe slopes the oil level in the engine crankcase must be at the FULL mark Check the level on the ENGINE LOW IDLE side of oil level gauge 1 5 If necessary remove the oil filler cap 2 and add oil Clean the filler cap and install the filler cap 6 Close the engine access door 156 Maintenance Section Engine Oil Sample Obtain SEBU8593 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 opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Obtain the sample of the engine oil as close as possible to the recommended sampling interval In order to receive the full effect of S O S oil analysis establish a consistent trend of data In order to establish a pertinent history of data perform consistent oil s
15. quantity from the bevel gear case g02505777 Illustration 280 Power train oil filler cap 9 Locate power train oil filler cap 4 The power train filler cap is in the compartment below the cab fresh air filter on the left hand side of the machine 10 If necessary remove the power train oil filler cap and add oil 11 Clean the power train oil filler cap and install the power train oil filler cap 103656528 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 281 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 on the transmission 5 Install the bottom guard Reference See Operation and Maintenance Ma
16. 15A 15A Flood 15A e Cleaning of the Hydraulic Tank Blower Wipers Volt Wakeup 6 15A 15A Monitor Auxiliary e Failure of the Fan Motor 10A Power 15A e Failure of the Fan Pump 7 10A Spare Relay Dual Starter Relay e Failure of the Implement Pump 8 15A e Failure of the Steering Motor e Failure of the Steering Pump e PCR Engine Overhaul Cab 9 Pressure 1 Park the machine on a level surface Lower the 10A Cyclinder Pressurizer Relay work tool to the ground Engage the parking brake Floods Relay 10 Cyl Floods 15A 2 Turn the engine start switch key to ON a ROPS 3 Move the hydraulic control levers through all of the positions in order to release pressure Floods 15A FWD ROPS p p Floods Relay Ingress Relay 4 Turn the engine start switch key to OFF 12 Horn 10A Remote 13 Seat15a KeYSW Control Spare 15A 10A 15A Nozzle Advis Instr Spare 10A 14 Cluster Converter Heat 15A 15A 15A 15A Condns2 Accug2 Engine 15 45A 15A ECM 15A Spare 15A Eng Xmsn 16 conons Monitor Spare Spare 15A 10A 15A SEBU8593 175 Maintenance Section Hydraulic System Filter Screens Clean 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
17. 7340 070 If equipped Use commercially available window cleaning solutions to clean the windows One wiper blade is used to clean the rear window In order to clean the outside of the rear window from the ground use a long pole gt 7 AS _ g02107477 Illustration 329
18. Inspect ue eeeeeeeeeeeeneeeeeeeenteeeeeeaaes 136 Power Train Oil Change esseere 182 Power Train System Oil And Screens Change Cleatn noen ran a ai 187 Rollover Protective Structure ROPS Inspect 195 Winch Oil and Breather Change Clean 201 Every 2000 Service Hours or 1 Year Engine Mounts and Equalizer Bar Inspect 153 Final Drive Oil Change 163 Final Drive Seal Guard Packing Replace 166 Hydraulic System Oil Change n 176 Track Roller Frame Inspect 2 0 0eeee 199 Track Roller Frame Guides Inspect 199 Every Year Refrigerant Dryer Replace 0 ee 193 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace cccccceceeeeeeeeeeeeeeeeeeees 195 Every 4000 Service Hours Electronic Unit Injector Inspect Adjust 149 Engine Mounts and Crankshaft Vibration Damper INSPOCE E EE E EE 152 Engine Valve Lash Check Adjust eeee 160 Engine Valve Rotators Inspect eee 160 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 146 Cooling System Water Temperature Regulator Replace acid sche ai eerie Ree 148 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 144 136 Maintenance Section Backup Alarm Test SEBU8593 104354571 Backup Alarm Test SMCS Code
19. LOW IDLE HOT OIL side of the oil level gauge This procedure is the only accurate way to check the oil level Note When you are operating the machine on severe slopes the quantity of oil in the power train can be increased up to 10 percent When you are operating with the increased oil quantity prolonged operation in some machines can cause high power train oil temperatures After the work on the severe slopes has been completed drain the excessive oil quantity from the bevel gear case g02505777 Illustration 292 Power train oil filler cap 3 Locate power train oil filler cap 4 The power train filler cap is in the compartment below the cab fresh air filter on the left hand side of the machine 4 If necessary remove the power train oil filler cap and add oil 5 Clean the power train oil filler cap and install the power train oil filler cap 104352389 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 opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice T
20. canister Turn the canister clockwise Hand tighten the canister Tighten the clamp around the canister 5 Close the engine access door 104333268 Final Drive Oil Change SMCS Code 4050 535 FLV Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product 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 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Illustration 233 g01394195 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 164 Maintenance Section Final Drive Oil Level Check SEBU8593 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 Refi
21. hand cab entry door reference only 2 Fuel shutoff valve 3 Fuel shutoff valve handle 1 Locate fuel shutoff valve 2 The valve is inside the enclosed compartment above the fender forward and below the fuel tank fill cap on the left hand side of the machine 2 Turn red colored handle 3 to close valve 3 Open left hand engine access door g02496276 Illustration 247 4 Remove the secondary filter and the tertiary filter 4 Discard the fuel filters properly 5 Clean the filter bases Make sure that all of the old seals are removed 6 Install the new filters Coat the seals of the new filters with clean diesel fuel 7 Install the new filters by hand When the seals contact the base tighten the filters according to the instructions on the filters Rotation index marks are positioned on the filters at 90 degree intervals Use these rotation index marks as a guide when you tighten the filters 8 Turn red colored handle 3 in order to open the fuel valve 9 After the fuel filters are replaced turn the key to the ON position Leave the key in the ON position for 2 minutes This action allows the system to fully prime 10 Start the engine and run the engine Check filters 4 for leaks 11 Close the engine access door 172 Maintenance Section Fuel Tank Cap Filter and Strainer Replace Clean SEBU8593 104341911 Fuel Tank Cap Filter and Strainer Replace Clean SMC
22. 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 5 Clean the inside of the air cleaner housing 4 Keep the secondary filter element in place while you clean the housing 6 Install a new primary air filter 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 7 Push the filter element firmly in order to properly seat the element Write the date on the element if the primary element is replaced 8 Install the air cleaner cover 9 Close the engine access door SEBU8593 151 Maintenance Section Engine Air Precleaner Clean Secondary Filter NOTICE Always replace the secondary filter element Never attempt to reuse the filter by cleaning The secondary filter element should be replaced at the time the primary element is serviced for the third time NOTICE The filter should be kept in service for no longer than 1 year NOTICE Always leave the secondary filter element in place while you clean the air cleaner housing 1 Open the engine access door Illustration 204 g02105115 2 Remove the air cleaner housing cover 1 3 Remove the primary filter element 2 Refer to the section Primary Filter 4 Clean the inside of the air cleaner
23. multigrade oil types are met When these require ments 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 inter val If you select an interval for oil and filter change that is too long you may damage the engine CAT oil filters are recommended Recommended multigrade oil types are listed in Table 25 Do not use single grade oils SEBU8593 157 Maintenance Section Engine Oil and Filter Change 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 25 Also refer to Manual SEBU5898 Cold Weather Recommendations Poor maintenance of air filters or of fuel filters requires reduced oil change intervals See your Caterpillar dealer for more information if this product will experience abnormally harsh operating cycles or harsh environments Table 25 DOT Series Engine Oil Change Interval Operating Conditions Normal Severe Multi d E Fuel Altitude oi Type High Sulfur above Load from 1830 m Factor 9 3 6000 ft to 0 5 Cat DEO Preferred 500 hr 500 hr 500 hr 250 hr ECF 1 10 0 minimum 500 hr 500 hr 500 hr 250 hr TBNO Preferred ECF 1 250 TBN 500 hr 500 hr
24. 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 Cooler Cores All machine arrangements have a remote mounted a c condenser core and a single plane of the following cores hydraulic oil cooler core radiator core and aftercooler core Additionally these arrangements may 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 pressurized air wear a protective 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 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 will need to be done a
25. power train oil level gauge 5 The power train oil level gauge is located behind the angled access cover that is rearward of the left hand engine access door BRS OO HO I OI ISIC SSS EE RERE RELER OEE EE Illustration 275 g01423532 20 Maintain the oil level within operating range X between the ADD mark and the FULL mark on the oil level gauge a When the engine is stopped and the oil is cold ambient temperature maintain the oil level on the ENGINE STOPPED COLD OIL side of the oil level gauge b When the engine is running and the oil is hot operating temperature maintain the oil level on the ENGINE LOW IDLE HOT OIL side of the oil level gauge High Speed Oil Change If Equipped Open the engine access door on the left hand side of the machine Swing up the lower guard assembly to reveal the high speed oil change connection fittings g02486238 Illustration 276 1 Engine high speed oil change connection fitting if equipped reference only 2 Power train high speed oil change connection fitting if equipped Power train high speed oil change connection fitting if equipped 2 can be used with additional equipment to change the power train oil The high speed oil change removes oil only 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 The filters will still need
26. 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 opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Case Drain Oil Filter Illustration 259 g02503797 Front angle view of hydraulic tank 1 Filler cap 2 Filter element assembly 3 Pressure vacuum breaker valve 4 Oil level sight gauge 178 Maintenance Section Hydraulic System Oil Level Check SEBU8593 Illustration 260 g02503136 Filter element assembly removed from tank and disassembled 5 Cover retaining nut and washer four sets 6 Filter cover 7 Cover o ring seal 8 Retaining stud 9 Filter element 10 Filter retainer 11 Filter retainer o ring seal 12 Locknut 1 Press the button on pressure vacuum breaker valve
27. suitable cover over discon nected fuel system component SEBU8593 169 Maintenance Section Fuel System Primary Filter Clean Replace Illustration 242 g02494956 Electric Fuel Priming Pump Primary Fuel Filter and Water Separator Assembly Illustration 243 g02116797 1 Element 2 Bowl 3 Drain 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 104339453 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 openin
28. the coolant to drain into a suitable container 6 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 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 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 7 Close drain valve 4 then remove the drain pipe if previously installed Install plug 3 8 Replace access cover 2 9 Add the ELC solution See the following 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 10 After the cooling system has been filled perform the following procedures during i
29. the oil change even longer Consult your Cat dealer for details When Required Battery Battery Cable or Battery Disconnect Switch R6plaCe icenttis cite ttt tah Sot a iea ee a 136 Camera Clean Adjust ccceesseeeeeeettteeeeeeees 140 Cooler Cores and A C Condenser Clean 141 Cutting Edges and End Bits Inspect Replace 149 Engine Air Cleaner Element Dual Element Box Type Replace ccccccccceeeessncceceesseneeeertenseees 149 Engine Air Precleaner Clean ee 152 Equalizer Bar Center Pin Measure 161 Equalizer Bar End Pins Measure 161 Ether Starting Aid Cylinder Replace 163 Fuel System Prime ccececceeeeeeeeeeenteeeeeeenaaes 168 Fuses and Circuit Breakers Replace Reset 173 Hydraulic System Filter Screens Clean 174 Oil Filter Inspect ec eeeeceeceeeeeeeeteeeeeseeeteeeeees 181 Power Train Scavenge Screen Clean 186 Radiator Core Clean cceceeeeeeecceeeeeeeeeeeeees 191 Radiator Pressure Cap Clean Replace 191 Ripper Tip and Shank Protector Inspect ReplaGe mohera endene N fee tenet inl 194 Torque Converter Scavenge Screen Clean 197 Winch Wire Rope Install 0 eeeeeeeeee 202 Window Washer Reservoir Fill a nn 203 Window Wipers Inspect Replace 0 203 Windows Clean 2 eccecceeeeee
30. the protective cap 3 Obtain a coolant sample while the engine is running and at the correct operating temperature For additional information about coolant analysis see Operation and Maintenance Manual SEBU6250 Cooling System Specifications General Coolant Information or consult your Caterpillar dealer 4 Replace the protective cap Close the right hand side engine access door Submit the sample for Level 2 analysis 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 always operate the engine with a thermostat Depending on load failure to operate with a thermo stat could result in either an overheating or an over cooling condition Reference Refer to Disassembly and Assembly Water Temperature Regulator Remove and Disassembly and Assembly Water Temperature
31. 3 on top of hydraulic oil tank in order to relieve any tank pressure Slowly remove filler cap 1 2 Remove filter cover retaining nuts and washers 5 3 Remove filter element assembly 2 4 Remove locknut 12 and retainer 10 from stud 8 Filter retainer o ring seal 11 will remain installed in the retainer groove The seal is shown as removed from the retainer for clarity of illustration only 5 Remove filter element 9 Properly discard the filter element 6 If stud 8 was loosened from cover 6 during the removal of the retaining nut tighten the stud to a torque of 35 7 N m 25 9 4 Ib ft 7 Wash the cover and the retainer in clean nonflammable solvent 8 Inspect cover seal 7 and filter retainer seal 11 Replace the seals if the seals are damaged 9 Install a new filter element 9 10 Install the clean retainer and the locknut Tighten the locknut to a torque of 10 1 5 N m 7 1 Ib ft 11 Install the filter assembly Tighten the cover retaining nuts to a torque of 45 7 N m 32 5 Ib ft 12 Maintain the hydraulic oil to the FULL mark in the oil level sight gauge 4 13 Install the hydraulic tank filler cap 104349199 Hydraulic System Oil Level Check SMCS Code 5056 535 FLV 7479 At operating temperature the hydraulic tank is hot and under pressure Hot oil and components can cause personal in jury Do not allow hot oil or components to contact sk
32. 477310 Illustration 192 3 Cleanout Slot Behind Access Cover 1 At the proper cleaning area park the machine in NEUTRAL and engage the parking brake 2 Depress the fan control switch and hold for 3 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 4 Open both engine access doors 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 3 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 144 Maintenance Section Cooling System Coolant ELC Change SEBU8593 8 Turn off the air supply when the nozzle clea
33. 7406 081 In order to test the alarm for proper functioning turn the engine start switch to the ON position g02509537 Illustration 176 Direction control switch located on steering control Apply the service brake Release the parking brake Move the direction control switch to the REVERSE position The backup alarm should start to sound immediately The backup alarm will continue to sound until the direction control switch is moved to the NEUTRAL position or to the FORWARD position ue Illustration 177 g02509637 Location of backup alarm 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 104355233 Battery Inspect SMCS Code 1401 040 Illustration 178 g02510279 Left hand battery and window washer fluid reservoir compartment Left hand guard rail assembly removed for illustration 1 Battery terminals and terminal covers 2 Compartment access cover in opened position 3 Retainers Note Perform the following procedures at every 1000 hour interval Check the following areas more often as required 1 Open the battery access cover 2 The battery access cover is on the left side of the machine next to the operator compartment 2 Tighten retainers 3 on the batteries at every 1000 hour interval 3 Clean the top of the batteries with a clean cloth Keep termina
34. BEFORE OPERATION Operation and Maintenance Manual Excerpt 2010 Caterpillar All Rights Reserved CATERPILLAR CATERPILLAR Hti Operation and Maintenance Manual DST Track Type Tractor TWG1 Up Machine 134 Maintenance Section Maintenance Interval Schedule SEBU8593 104209341 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 All adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging are included 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 Refer to the maintenance procedure for any other exceptions that may change the maintenance intervals Note Before each consecutive interval is performed all maintenance from the previous interval must be performed Note If Cat HYDO Advanced hydraulic oils are used the hydraulic oil change interval is extended to 3000 hours S O S services may extend
35. Inspect the final drive for debris or abrasive substances that are wrapped around the final drive such as cable or wire 3 If the area inside the guard is packed with debris or abrasive substances remove guard 1 and clean the debris or abrasive substances from the guard and the final drive 4 Install the guard 1 onto the final drive 5 Install the inspection cover 2 on the guard 1 Reference Refer to Operation and Maintenance Manual Final Drive Seal Guard Packing Replace If Equipped for more information on the procedure to replace the packing 166 Maintenance Section Final Drive Seal Guard Packing Replace SEBU8593 102777624 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 Rep
36. 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 screen 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 Power Train System Oil Level Check in order to fill with oil 102796323 Track Check Adjust SMCS Code 4170 036 Illustration 308 g01125194 Check the track adjustment Check the track for wear and for excessive dirt buildup 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 spr
37. S Code 1273 070 STR 1273 070 Z2 Illustration 248 g02498142 1 Fuel tank cap with filter and strainer 2 Fast fill adapter connection fitting 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 il TATTOO 02 CAT eal _ Po Illustration 249 g01110732 Detailed view of fuel tank cap components 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 assembly 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 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 248 Machines that are equipped with a fast fill fuel adapter 2 have identical fuel caps as system
38. a 30 psi for cleaning purposes 3 The filter element can be cleaned by using pressurized air Use a maximum air pressure of 205 kPa 30 psi Direct the air from the clean side to the dirty side 4 Inspect the element for damage Inspect the gaskets for damage Replace damaged filters 5 Install filter element 3 and install filter cover 1 Fasten three clamps 2 Note Use three points of contact when you install the cab filter fresh air Note Clean the filters more often in dusty conditions 104317289 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 seat base in the cab Illustration 186 g02476617 Area to left of operator seat base Seat assembly removed to enhance visibility 1 Unscrew fastener 1 to cover of recirculation filter 2 and remove the cover Remove the recirculation filter element Access to the filter can be improved by sliding the seat fully forward Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressurized air wear a protective 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 pressurized air Use a maximum air pressure of 205 kPa 30 psi
39. ad 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 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 SEBU8593 163 Maintenance Section Ether Starting Aid Cylinder Replace 104331692 Ether Starting Aid Cylinder Replace SMCS Code 1456 510 CD Illustration 231 g02487356 1 Open the left hand engine access door of the machine The ether canister is mounted inside the compartment on the side of the engine g02488766 Illustration 232 2 Loosen retaining clamp 1 Remove old canister 2 by turning the canister counterclockwise 3 Remove the old gasket Install the new gasket 4 Install the new
40. amplings that are evenly spaced 1 Before you obtain an oil sample operate the machine until the oil is warm and circulated 2 Open the engine access door on the left hand side of the machine Illustration 218 g02482356 Engine oil sampling valve 3 Remove the protective cap 4 Obtain a sample of the engine oil from the engine oil sampling valve Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Services 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 increasing the engine speed may be necessary 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 access door For additional information about oil sampling consult your Cat dealer 104327550 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 if operating conditions and recommend ed
41. and size only Otherwise electrical damage can result If itis necessary to replace fuses frequently an electri cal problem may exist Contact your Caterpillar dealer Illustration 251 g02511219 The fuse panel is behind the access cover that is below the left armrest of the operator seat F9 10A F6 10A F38 15A CB4 15A O Bl oml D F4 fF F3 F2 jH F cA 15A oe 15A F13 15A Mn EKA EKA F23 15A A 7 F18 15A F14 c 15A E z F34 1454 F35 F21 F24 20A 15A 15A F22 a F28 15A i OF F20 F29 F30 x Illustration 252 902163853 174 SEBU8593 Maintenance Section Horn Test Table 27 102054663 Primary Fuse Panel Horn Test SMCS Code 7402 081 A B Cc D Test the horn on a daily basis Press downward on the horn button in order to sound the horn If the horn j Second Auxiliary parei Imp ECM does not oe ee the necessary repairs before ou operate the machine Brake 10A Power 15A ECM 15A 15A y p 2 Prod Link Engine Navigator Conv 104343851 10A ECM 15A 10A Power 20A P Hydraulic System Filter aA Screens Clean Fuel Prime Fender Floods Relay Relay SMCS Code 5068 4 15A The screen should be cleaned especially when one Rip Impl Fuel Tank R ROPS Accugrade of the following situations have occurred 5 Control Ripper HID 15A
42. anual 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 3 Inspect the filler cap and the filler cap seal for debris for foreign material or for damage Clean the filler cap with a clean cloth Replace the radiator cap if the filler cap is damaged 4 Install the filler cap 5 Inspect the radiator core for debris Clean the radiator core if necessary Illustration 199 g02071339 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 core to dry completely before operating the machine in the work mode 104320903 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 148 Maintenance Section Cooling System Water Temperature Regulator Replace SEBU8593 NOTICE Care must be taken to ensure that fluids are contai
43. ap 2 Slowly remove the filler cap in order to relieve system pressure 3 Inspect the filler cap for damage for deposits or for foreign material Clean the filler cap with a clean cloth Replace the filler cap if the filler cap is damaged 4 Install the filler cap i02017071 Recoil Spring Compartment Oil Level Check SMCS Code 4158 535 OC Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Illustration 296 g01042644 1 Remove all of the 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 297 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 SEBU8593 193 Maintenance Section Refrigerant Dryer Replace 104353272 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 fitt
44. ar pads for cracked rubber and for missing portions of rubber Consult your Caterpillar dealer for replacement parts and for replacement instructions 104324335 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 Park the machine on level ground 2 Open the engine access door on the left hand side of the machine Illustration 216 g02480336 3 Remove engine oil level gauge 1 Examine the oil level gauge in order to determine the engine oil level The gauge can be read on both sides One side is marked ENGINE STOPPED The other side is marked ENGINE LOW IDLE BRS OO CO I OT ISIC ee BEE RERE ELELEE EO EET Illustration 217 g01423532 4 Maintain the oil level within operating range X between the ADD mark and the FULL mark on the oil level gauge a When the engine is stopped and the oil is cold ambient temperature maintain the oil level on the ENGINE STOPPED side of the oil level gauge This method should be used as reference only before the engine is started b When the engine is running and the oil is warm operating temperature maintain the oil level on the ENGINE LOW IDLE side of the oil level
45. ase Be sure that all of the old seal is removed 7 Coat the seal of the new filter element with clean diesel fuel 8 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 rotation 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 A Caterpillar strap wrench or another suitable tool may be needed to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter 9 Coat the seal of the water separator bowl with clean diesel fuel Install the water separator bowl to the filter element 10 Turn red colored handle 3 in order to open the fuel valve 11 After the fuel filter is replaced turn the key to the ON position Leave the key in the ON position for 2 minutes This action allows the system to fully prime 12 Start the engine and run the engine Check filter 4 and water separator bowl 5 for leaks 13 Close the engine access door 104340112 Fuel System Secondary Filter
46. bration Damper Inspect SMCS Code 1152 040 1205 040 Damage to the vibration damper or failure of the vibration damper will increase torsional vibrations These vibrations will result in damage to the crankshaft and in damage to the other engine components A deteriorating vibration damper will cause excessive gear train noise at variable points in the speed range See the Service Manual Engine Disassembly and Assembly for the procedure to install a new damper Caterpillar recommends replacing the damper for any of the following reasons e The engine has had a failure because of a broken crankshaft The damper can be used again if none of the above conditions are found The damper can be used if the damper is not damaged In the damper a wobble can occur on the outer ring Some of the wobble of the outer ring is normal If a wobble is present replacement of the damper is not necessary You can confirm an acceptable wobble by seeing the Service Manual Engine Disassembly and Assembly for the procedure to check the damper i wy ECTION A A g01066628 Illustration 208 Marks of the damper are on the hub and on the ring These marks will indicate the condition of the vibration damper If the marks are not in alignment the rubber seal between the ring and the hub has separated from the ring and or from the hub Install a new damper if the marks are not in alignment Note Refe
47. cators 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 pointers 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 104349450 Lift Cylinder Yoke Bearings Lubricate SMCS Code 5102 086 BD Illustration 264 g02504616 The grease fittings are located 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 SEBU8593 181 Maintenance Section Oil Filter Inspect 102106227 Oil Filter Inspect SMCS Code 1318 507 3067 507 5068 507 Inspect a Us
48. cess cover on top of the hood forward of the engine air precleaner Loosen the radiator cap slowly in order to relieve pressure Remove the radiator cap 2 Draining some coolant from the radiator may be necessary 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 regulations and mandates 3 Add proper mixture 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 5 Maintain the coolant at the proper level as the thermostat opens and air is purged from the system Refer to Operation and Maintenance Manual Cooling System Coolant Level Check 6 Inspect the radiator cap for any signs of damage Replace if necessary Install the radiator cap SEBU8593 147 Maintenance Section Cooling System Coolant Level Check
49. ch 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 Ground Engaging Tool G E T Fasteners 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 in 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 104316216 Engine Air Cleaner Element Dual Eleme
50. changed See Operation and Maintenance Manual Power Train Oil Filter Replace SEBU8593 185 Maintenance Section Power Train Oil Filters Replace 104357412 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 opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Two filters are located under the fuel tank The fuel tank is on the rear of the machine There is one filter under each side of the fuel tank 4 Inspect the seals If the seals are damaged replace the seals 5 Install the new filter elements Install the filter element housings Install the filter housing drain plugs 6 Start the engine Illustration 277 g01387583 1 Remove drain plug 1 in order to remove a small amount of oil from each filter housing 2 Use a wrench in order to remove the filter housings 2 Remove
51. de 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 both the right hand and left hand engine access doors 4 Rotate belt tensioner 1 clockwise in order to release the tension from the belt with a 12 7 mm 0 5 inch square drive tool 5 Remove the belt 6 Install the new belt Be certain that the belt is properly aligned in the grooves of crankshaft drive pulley 7 idler pulley 2 alternator pulley 4 and air conditioner compressor pulley 5 7 Allow the belt tensioner to rotate counterclockwise against the belt in order to provide proper tension 8 Close the engine access doors 9 Turn the battery disconnect switch to the ON position 104045481 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 Disable EAS Reference See
52. drain valve 2 and drain the oil into a suitable container Illustration 285 g01043086 Rear view 7 Access drain valve body 3 for the transmission at the rear of the machine as shown 8 Remove plug 5 from the bottom of drain valve body in the transmission Install a 12 7 mm 5 inch pipe into the drain valve body 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 in the transmission oil filters that are located at the rear of the machine 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 1 Drain the oil into a suitable container before removing any screen 2 Remove the covers Remove the screens 3 Clean the three screens in clean nonflammable solvent 4 Install the screens Install the covers Torque Converter SOG ZZ l Illustration 286 g01051956
53. dy of the transmission Install a 12 7 mm 0 5 inch pipe into the transmission drain valve body Use a 12 7 mm 0 5 inch pipe with 1 2 14 NPTF threads 9 Clamp a hose to the pipe in order to direct the oil into a suitable container 10 Open the transmission drain valve and drain the oil into a suitable container 11 Close the drain valve on the torque converter Close the drain valve on the transmission 12 Remove the hoses and remove the pipes from the drains Clean the oil drain pipe plugs and install the oil drain pipe plugs 13 Remove the swivel or remove the pipe from the drain in the bevel gear case The drain valve will close Clean the oil drain plug and install the oil drain plug 14 Change the filter elements See Operation and Maintenance Manual Power Train Oil Filter Replace 184 Maintenance Section Power Train Oil Change SEBU8593 g02505777 Illustration 273 Power train oil filler cap 15 Locate power train oil filler 4 cap The power train filler cap is in the compartment below the cab fresh air filter on the left hand side of the machine 16 Remove the power train oil filler cap 17 Add oil To determine the correct amount of oil see Operation and Maintenance Manual Capacities Refill 18 Clean the power train oil filler cap and install the power train oil filler cap Illustration 274 g02505876 19 Locate
54. e joint 8 at the ends of the inner packing 7 Illustration 240 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 9 168 Maintenance Section Fuel System Prime SEBU8593 Illustration 241 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 104338609 Fuel 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 1 Turn the key to the ON position The electric fuel priming pump is activated in this way 2 Leave the key in the ON position for 2 minutes This action allows the sys
55. e 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 870 90 N m 650 65 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 870 90 N m 650 65 Ib ft Then tighten the bolts for an additional 120 degrees SEBU8593 199 Maintenance Section Track Pins Inspect 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 This Illustration 313 g01021628 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 pi
56. ect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Illustration 262 g02502498 1 Left hand cab entry door reference only 2 Hydraulic oil sampling valve 3 Steering charge filter reference only Obtain a sample of the hydraulic oil from sampling valve 2 The sampling valve is located on the base of the steering charge filter 3 The filter is inside the enclosed compartment forward and below the fuel tank fill cap on the left hand side of the machine above the fender Remove the protective cap from the oil sampling valve 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
57. ed Filter for Debris Illustration 265 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 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 104337689 Pivot Shaft Oil Level Check SMCS Code 4153 535 FLV Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Illustration 266 g02493356 Pivot shaft oil level reserv
58. eeeeeseeeeeneeeaeees 203 Every 10 Service Hours or Daily Backup Alarm Test 2 ceceeceeeeeeeeeeeteeeees 136 Braking System Test 0 138 Cab Filter Fresh Air Clean Inspect Replace 139 Cooling System Coolant Level Check 147 Engine Oil Level Check cccccceeeeeeeeeeeeneeees 155 Fuel System Primary Filter Water Separator Drait nesre ese tate neces tia eevee e a ae cokt 168 Fuel Tank Water and Sediment Drain 172 IONE lt TOSE a otter tears E esata redhat 174 Hydraulic System Oil Level Check sasse 178 Indicators and Gauges Test 1 179 Pivot Shaft Oil Level Check 181 Power Train System Oil Level Check 189 Seat Belt Inspect oe eee eeeeeeceecteeeeeeeeees 195 Walk Around Inspection ceeeeeeeeeeeeeeteees 200 Every 50 Service Hours Bulldozer Tilt Brace and Tilt Cylinders Lubricate mia ne eee 139 Cab Filter Recirculation Clean Inspect Replace iii i ihai i iaaa a ia 140 Lift Cylinder Yoke Bearings Lubricate 180 Ripper Linkage and Cylinder Bearings Eolia E EE cceteaes tee area EEA 194 Track Pins Inspect cecceeceeeeeeeeeeeeseteeeaees 199 Every 250 Service Hours Belt Inspect Adjust Replace eseeee 137 Engine Oil Sample Obtain a a 156 Engine Oil and Filter Change s es 156 Equalizer Bar End Pins Oil Level Check 162 Final Drive Oil Leve
59. etainers 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 SEBU8593 195 Maintenance Section Rollover Protective Structure ROPS Inspect 102016045 Rollover Protective Structure ROPS Inspect SMCS Code 7325 040 e ae po pono cy gi ee ry me NS g01042319 Illustration 302 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 1800 200 N m 1330 148 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 not weld reinforcement plates to the ROPS in order to repair the ROPS If the ROPS has any cracks in the welds in the castings or in any metal section consult your Caterpillar dealer for repairs 102429589 Seat Belt Inspect SMCS Code 7327 040 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 Illustrati
60. ft hand side of the bottom engine guard Illustration 220 g02485637 Engine oil drain adapter and drain valve behind crankcase drain access cover 2 Remove drain plug 1 from the drain adapter SEBU8593 159 Maintenance Section Engine Oil and Filter Change 3 Install a 25 4 mm 1 00 inch pipe into the drain adapter The pipe requires a 1 11 1 2 NPTF pipe thread A drain hose may be attached to the pipe to aid in draining ai x 4 Open the drain valve 2 Allow the oil to drain into a suitable container SSS le b EEEE E ESE ODL NSE E E SE E EE ESEE E E E ES S BEIER ERRER RRR ERRE 5 When the oil has completed draining from the Illustration 222 901423532 crankcase close the drain valve 2 Remove the pipe Install the drain plug 1 Install the access 11 Maintain the oil level within operating range X cover between the ADD mark and the FULL mark on the oil level gauge nir oor a When the engine is stopped and the oil is cold a a ambient temperature maintain the oil level Ie on the ENGINE STOPPED side of the oil level gauge This method should be used as reference only before the engine is started Ww gt o When the engine is running and the oil is warm operating temperature maintain the oil level on the ENGINE LOW IDLE side of the oil level gauge This procedure is the only accurate way to c
61. g any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat 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 170 Maintenance Section Fuel System Secondary Filter Replace SEBU8593 N CNY TALS J NF il Illustration 244 1 Left hand cab entry door reference only 2 Fuel shutoff valve 3 Fuel shutoff valve handle g02495496 1 Locate fuel shutoff valve 2 The valve is inside the enclosed compartment above the fender forward and below the fuel tank fill cap on the left hand side of the machine 2 Turn red colored handle 3 to close valve 3 Open left hand engine access door Illustration 245 g02495717 4 Drain water separator bowl 5 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 5 Remove filter element 4 Properly discard the filter element 6 Clean the filter b
62. hanism are housed within the screen Take care to remove all components for cleaning and inspection Clean all components with clean nonflammable solvent 176 Maintenance Section Hydraulic System Oil Change SEBU8593 10 Install the case drain valve mechanism spring and screen being careful that components are installed properly Make certain that the valve mechanism is seated properly and that the valve mechanism and spring are not bound up and can operate freely 11 Install the implement return screen 12 Replace hydraulic tank access cover 6 13 Fill the hydraulic tank Reference For the correct procedure refer to Operation and Maintenance Manual Hydraulic System Oil Change 14 Replace filler cap 1 104345029 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 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 opening any compartment or disassembling any com ponent con
63. heck the oil level 02484276 Note When you operate the machine on severe slopes the oil level in the engine crankcase must be t the FULL k Check the level on the ENGINE 6 Open the engine access door on the left hand side haa IESI n Ea B G of the machine Remove engine oil filter element 3 and discard the engine oil filter element properly Make certain that all of the old filter seal is removed from the filter base 5 LE te _ YEN ao 0 fo Illustration 221 12 If necessary remove the oil filler cap 4 and add oil Clean the filler cap and install the filler cap For additional information about oil types see Special 7 Apply a thin coat of oil to the seal on the new filter Publication SEBU6250 eC aierpiller Machine Fluids Install the new engine oil filter element by hand R dations It Caterpillar d al When the gasket contacts the filter base tighten en ay a pay ae aoe cee a the filter element by an additional 3 4 turn 270 P degrees Rotation index marks are on the new High Speed Oil Change If Equipped filter element These rotation index marks are spaced at 90 degree intervals Use these rotation index marks as a guide for proper tightening Open the engine access door on the left hand side of the machine Swing up the lower guard assembly to reveal the high speed oil change connection fittings 8 Remove oil filler cap 4 Fill the crankcase with new oil See the to
64. housing 4 5 Remove the secondary filter element 3 Pull out in order to remove the element 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 104323137 Engine Air Precleaner Clean SMCS Code 1050 070 es Illustration 205 g02479240 g02280221 Illustration 206 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 152 Maintenance Section Engine Air Precleaner Clean SEBU8593 102014977 Engine Air Precleaner Clean SMCS Code 1050 070 Illustration 207 g01041703 1 Inspect the air inlet screen for dirt and for trash 2 Remove the screen Clean the screen if the screen is dirty 3 Inspect the precleaner tubes for dirt and for dust 4 Use pressure air to clean the tubes Put the tubes on a flat surface Direct the pressurized air into the tubes from the top This loosens up the dirt Install the screens NOTICE Service the air cleaner only with the engine stopped Engine damage could result 102091921 Engine Mounts and Crankshaft Vi
65. 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 D9T is every 500 hours If the operating conditions fuel rates and recommended oil types for your engine are listed in the table25 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 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 D9T exceeds 51 L 13 5 US gal per hour follow the High Load Factor recommendations in Table 25 To determine average fuel consumption measure average fuel cons
66. hts 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 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 dried completely 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 dried completely Allow the machine to sit overnight before operating the machine in the work mode Typical Cleaning Procedure That Uses Compressed Air All machine arrangements may 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 902
67. idler Lower the machine onto the block 200 Maintenance Section Walk Around Inspection SEBU8593 Tha g01021579 Illustration 316 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 De Illustration 317 g01021605 Some components are removed for clarity 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 D TD WYO Lat Nig OP EN SOP SS ih g01021583 Illustration 318 4 Put a mark on the tubular section of the front roller frame This mark should correspond with the mark on the rear roller frame Measure the distance between the two marks on the front roller frame If the distance between the two marks is greater than 4 5 mm 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 A ee Illu
68. in 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 hand side of the machine above the fender Illustration 261 g01042594 Oil level sight gauge located on front of hydraulic oil tank 1 Maintain the oil level to the FULL mark in the sight gauge Check the oil level when the oil is cold ambient temperature Verify that the oil level is below the FULL mark before you remove the filler cap 2 Ifthe hydraulic system requires additional hydraulic oil press the button on the pressure vacuum breaker valve to relieve any tank pressure Slowly remove the filler cap Add oil through the filler tube SEBU8593 179 Maintenance Section Hydraulic System Oil Sample Obtain 3 Clean the filler cap and install the filler cap 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 prepared to coll
69. in a straight line behind the tractor 2 Install the ferrule end into the socket 3 Reel in the cable SEBU8593 203 Maintenance Section Window Washer Reservoir Fill 104357730 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 Illustration 327 g02511337 Left hand battery and window washer fluid reservoir compartment Left hand guard rail assembly removed for illustration 1 Compartment access cover in opened position 2 Window washer fluid reservoir filler cap fluid reservoir is located in the compartment with the batteries on the left hand side of the machine Access cover 1 is on the left hand side of the machine next to the operator compartment Remove window washer fluid reservoir filler cap 2 in order to fill the window washer fluid reservoir Gee Window Washer The window washer S 104358049 Window Wipers Inspect Replace If Equipped SMCS Code 7305 040 7305 510 4 G To E a g02511477 Illustration 328 Inspect the front window wiper blade the right hand door window wiper blades the left hand door window wiper blades and the rear window wiper blade Replace any wiper blades that are damaged or worn Replace any wiper blades that streak the windows 104066452 Windows Clean SMCS Code 7310 070
70. ing 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 prop erly remove the refrigerant from the air condition ing system Illustration 298 g02508540 Refrigerant dryer The refrigerant dryer is located inside the enclosed compartment with the fuel shutoff valve and the steering charge filter This compartment is above the fender forward and below the fuel tank fill cap on the left hand side of the machine Se i ages Illustration 299 g01017640 Note The R 134a refrigerant dryer 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 Reference For the correct procedure refer to Air Conditioning and Heating Service Manual SENR5664 or the Disassembly a
71. ir conditioner condenser unit outside of the right hand cab window 142 Maintenance Section Cooler Cores and A C Condenser Clean SEBU8593 Inspect Note Adjust the frequency of inspection according to the effects of the operating environment Illustration 191 g02476830 1 Right hand Engine Access Door 3 Cleanout Slot Located Behind Access Cover Turn off the engine Open both engine access doors 1 Inspect the cooling system for the following conditions coolant leaks oil leaks damaged fins and tubes Inspect the following parts of the cooling systems air lines connections and clamps for damage Make repairs for damage if necessary Note If parts of the aftercooler system 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 inch or 114 mm 4 50 inch 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
72. l Check ceeeceee 164 Track Check AdjuSt 0 ccccceeeeeteeeeeeeetteeeeeeeaaes 197 Winch Fairlead Rollers Lubricate 200 Winch Oil Level Check cceeceeeeeeeeeeeeees 201 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 Obtain a ridera EA 147 Electronic Unit Injector Inspect Adjust 149 Engine Valve Lash Check Adjust 00 160 Engine Valve Rotators Inspect e 160 Winch Oil and Breather Change Clean 201 Every 500 Service Hours Final Drive Oil Sample Obtain 08 164 Final Drive Seal Guard Inspect Clean 165 Fuel System Primary Filter Clean Replace 169 Fuel System Secondary Filter Replace 170 Fuel Tank Cap Filter and Strainer Replace Clean 0 cccceeeeeeeeeeeceeceeeeeeeeeeeteeeeees 172 Hydraulic System Oil Filter Replace 177 SEBU8593 135 Maintenance Section Maintenance Interval Schedule Hydraulic System Oil Sample Obtain 179 Power Train Breather Clean cccseeeeeeeeees 182 Power Train Oil Filters Replace 05 185 Power Train System Oil Sample Obtain 190 Recoil Spring Compartment Oil Level Check 192 Steering Charge Filter Replace n 196 Every 1000 Service Hours or 6 Months Battery
73. lacement of the Packing AN a SC Viz Ns fel Illustration 237 g00939700 4 Bolt 5 Washer 6 Retainer 1 Remove bolts 4 and washers 5 Remove retainers 6 Illustration 238 g01387828 Cross section view of seal guard 3 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 7 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 26 Required Parts Part Qty Description Number 189 6244 2 Seal packing 129 1928 1 Grease Note Each final drive seal guard requires two 189 6244 Seals packing The sections of packing are installed on top of each other in the groove of the seal guard SEBU8593 167 Maintenance Section Final Drive Seal Guard Packing Replace Illustration 239 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 th
74. ler tube Wash the filler strainer and the filler cap in clean nonflammable solvent Install the filler strainer inside the filler tube 6 Close the drain valve Remove the drain pipe and drain hose from the valve Clean the pipe plug and install the pipe plug 7 Change the hydraulic system filter See the Operation and Maintenance Manual Hydraulic System Oil Filter Replace 8 Fill the hydraulic oil tank See the Operation and Maintenance Manual Capacities Refill in order to determine the amount of hydraulic oil that is needed to fill the hydraulic oil tank SEBU8593 177 Maintenance Section Hydraulic System Oil Filter Replace 9 Inspect the filler cap gasket Replace the gasket if damage or wear is evident 10 Install the filler cap 11 Start the engine Run the engine for a few minutes Illustration 258 g01387544 12 Maintain the oil level to the FULL mark in sight gauge 3 Check with the attachments on the ground and with oil cold ambient temperature Add oil if necessary 13 Stop the engine For additional information about hydraulic system oil see Operation and Maintenance Manual SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 104348189 Hydraulic System Oil Filter Replace SMCS Code 5068 510 At operating temperature the hydraulic tank is hot and under
75. ll 7 Inspect the condition of the seal of the filler plug Replace the plug seal if the plug 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 102790608 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 234 g01394195 1 Position one final drive so that oil level mark 2 is horizontal with the oil filler plug 1 2 Remove oil filler plug 1 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 1 6 Repeat Step 1 to Step 5 in order to check the oil level in the other final drive 104356911 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 prepa
76. ls 1 clean and coat the terminals with petroleum jelly Install the terminal covers after you coat the terminals 1 Close the battery access cover 104355610 Battery Battery Cable or Battery Disconnect Switch Replace SMCS Code 1401 510 1402 510 1411 510 1 Turn the engine start switch key to the OFF position Turn all of the switches to the OFF position SEBU8593 137 Maintenance Section Belt Inspect Adjust Replace i Q Niaz i a nf E Illustration 179 g02510540 2 Locate the battery disconnect switch The battery disconnect switch is contained in the ground level service center which is located at the front of the left hand fender Turn the battery disconnect switch to the OFF position Remove the key 3 Disconnect the battery cable at the battery disconnect switch 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 facilit
77. ment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates When a Caterpillar Extended Life Coolant ELC is used an extender must be added to the cooling system See the 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 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 g02478039 Illustration 197 1 The filler cap is located beneath the ac
78. n 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 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 314 g01049034 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 frame relative to the rear roller frame Aa Illustration 315 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
79. n this manual for the procedure to change the transmission filters Illustration 282 g01043089 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 283 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 188 Maintenance Section Power Train System Oil And Screens Change Clean SEBU8593 Illustration 284 g01051888 Rear view 4 Remove plug 1 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
80. nd Assembly Manual for your machine Note A qualified mechanic should replace the components of the refrigerant system since special tooling and training are required 194 Maintenance Section Ripper Linkage and Cylinder Bearings Lubricate SEBU8593 101286780 Ripper Linkage and Cylinder Bearings Lubricate SMCS Code 6313 086 BD L4 l gt T i e 2 Es A lz Illustration 300 g00681900 Lubricate twelve grease fittings six per side Use MPGM Grease 100925689 Ripper Tip and Shank Protector Inspect Replace SMCS Code 6808 040 6808 510 6810 6812 040 6812 510 If equipped Illustration 301 g00550432 When the ripper tip is worn close to the shank replace the ripper tip When the shank protector is worn close to the shank replace the shank protector If the tip is too blunt the tip will not penetrate properly 1 Raise the ripper Place blocking under the ripper Lower the ripper onto the blocking The ripper should be high enough so that the ripper tip or the shank protector can be removed Do not place the ripper too high 2 If the ripper tip is worn drive out the pin Remove the tip and the shank pin retainer 3 Clean the shank pin retainer and the pin 4 Install the new tip and the retainer 5 Install the pin from the opposite side of the retainer 6 If the shank protector is worn drive out the pins Remove the shank protector 7 Clean the pin r
81. ndensation snow or ice For more information on WAVS refer to Operation and Maintenance Manual SEBU8157 Work Area Vision System 104317415 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 radiator core cools the engine coolant Illustration 189 g02476735 1 Aftercooler Core 2 Radiator Core 3 Cleanout Slot Located Behind Access Cover 4 Hydraulic Oil Cooler Core Radiator Core 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 Remote Air Conditioner A C Condenser Core In this machine arrangement the a c condenser core is remotely located A remote mounted a c condenser core is cooled by fans with electric drive Illustration 190 g02511127 A
82. ned during performance of inspection maintenance test ing adjusting and repair of the product 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 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat 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 Illustration 200 g02477345 1 Coolant Level Sight Glass 2 Coolant Sampling Valve 1 Park the machine on a hard level surface Set the engine at low idle speed Set the parking brake 2 Open the right hand side engine access door Use the location of the coolant tank and Coolant Level Sight Glass 1 for reference Locate Coolant Sampling Valve 2 and remove
83. ning of the left side cores is completed 9 Remove the air 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 104321556 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 beneath the access cover on top of the hood forward
84. nitial start up a Start the engine without the filler cap b Run the engine at low idle for 10 minutes c Then increase the engine speed to a high idle until the thermostat is open and the coolant level is stabilized d Maintain the coolant at the proper level as the thermostat opens and air is purged from the system Refer to Operation and Maintenance Manual Cooling System Coolant Level Check 11 Stop the engine Illustration 196 g02071339 12 Clean the radiator core with compressed air You may need to use water in order to remove debris 13 Allow the radiator core to dry completely before operating the machine in the work mode Reference See Operation and Maintenance Manual Cooling Cores 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 146 Maintenance Section Cooling System Coolant Extender ELC Add SEBU8593 104321966 Cooling System Coolant Extender ELC Add SMCS Code 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 opening any compart
85. nstall 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 Turn the pipe if used by hand only 3 Turn the swivel or pipe clockwise in order to open the internal drain valve Allow the oil to drain into a suitable container a Sa Illustration 270 g02505276 1 Drain valve body 2 Pipe plug 3 Drain valve 4 Remove the middle bottom guard to access the torque converter drain Remove pipe plug 2 from the bottom of drain valve body 1 on the torque converter Install a 12 7 mm 0 5 inch pipe into the drain valve Use a 12 7 mm 0 5 inch pipe with 1 2 14 NPTF threads 5 Clamp a hose to the pipe in order to direct the oil into a suitable container 6 Open drain valve 3 and drain the oil into a suitable container ERT ae Bi ee any ees CO A a Y Illustration 271 g01181367 Transmission drain access cover at rear of machine 7 Remove the access cover for the transmission drain plug The access cover is found at the rear of the machine Illustration 272 g01181338 Right side view 8 The transmission drain valve is the same type as the torque converter drain valve Remove the pipe plug from the drain valve bo
86. nt Box Type Replace SMCS Code 1054 510 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 150 Maintenance Section SEBU8593 Engine Air Cleaner Element Dual Element Box Type Replace 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 Do not use the filter for longer than one year Af U g02476028 Illustration 202 Box Type Engine Air Cleaner 1 Open the engine access door on the left hand side of the machine Illustration 203 g02105115 2 Remove the air cleaner housing cover 1 3 Remove the primary filter element 2 from the air cleaner housing 4 4 Mark the secondary filter element 3 in order to show that the primary filter element
87. nual Power Train System Oil and Screens Change Clean in order to fill with oil SEBU8593 187 Maintenance Section Power Train System Oil And Screens Change Clean 103649114 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 slight down pressure See the Operation and Maintenance Manual Power Train Oil Filter Replace i
88. ocket 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 198 Maintenance Section Track Check Adjust SEBU8593 Illustration 309 g01109482 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 is 130 10 mm 5 12 0 4 inch E Illustration 310 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 Loose Track Adjustment 6 We Ona ps This Illustration 311 g01019107 See the following Notice for maximum dimension D NOTICE Do not attempt to tighten track when the dimension between the front edge of the wear sleeve on the front track roller frame and the edge of the track roller frame support is 189 mm 7 4 inch or more Contact your Caterpillar dealer for track service or instructions 1 Remove the access cover Illustration 312 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 us
89. of the engine air precleaner g02477447 Illustration 193 1 Put the machine on a hard level surface set the parking brake and turn off the engine 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 2 Slowly loosen filler cap 1 in order to relieve system pressure Remove the filler cap Illustration 194 g02477496 3 Remove access cover 2 for the coolant drain The cover is located on the right side near the front of the bottom engine guard SEBU8593 145 Maintenance Section Cooling System Coolant ELC Change g02477560 Illustration 195 Coolant drain valve viewed through access hole in bottom engine guard 4 Remove plug 3 from the drain valve Install a 12 7 mm 5 inch drain pipe into the drain valve The pipe must have 1 2 14 NPTF threads Clamp a hose to the pipe in order to direct the coolant into a suitable container 5 Open drain valve 4 Allow
90. oir cap and oil level gauge 1 Open angled access cover 1 that is rearward of the left hand engine access door 2 Loosen cap oil level gauge 2 by turning the handle counter clockwise enough to lift out 3 Proper reservoir oil level is maintained by adding oil through the reservoir opening Maintain the oil level to the FULL mark on oil level gauge 2 Do not overfill Overfilling can cause hot oil to overflow the reservoir 4 Install the cap oil level gauge in the reservoir opening and tighten by turning clockwise until snug Note The initial fill of pivot shaft may trap air in the tube The level of the oil may fall as air escapes The reservoir must be filled several times to remain consistently full 182 Maintenance Section Power Train Breather Clean SEBU8593 Illustration 267 g01434353 3 Filler plug for pivot shaft compartment 4 Drain plug for pivot shaft compartment Check for seal leakage at the pivot shaft retainer The pivot shaft retainer is located on the main frame case If there is any sign of seal leakage refer to the appropriate Service Manual or consult your Caterpillar dealer for repairs Note If disassembly is required fill at filler plug 3 and at the oil reservoir after completion of repair 103649020 Power Train Breather Clean SMCS Code 3030 070 BRE S i LN 1 G2 Illustration 268 g01387604 Top view Some c
91. omponents are removed for clarity 1 Open the floorplate that is inside of the cab The breather attaches to the tube from the torque converter to the transmission case Unscrew and remove the breather 2 Clean the breather in clean nonflammable solvent 3 Install the breather and close the cover 104349897 Power Train Oil Change SMCS Code 4000 044 OC 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 opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Operate the machine in order to warm the power train oil The machine must be level Lower the attachments with slight down pressure Engage the parking brake switch Stop the engine 1 Power train oil is drained from beneath the machine Illustration 269 g01181288 Right hand side view SEBU8593 183 Maintenance Section Power Train Oil Change 2 Remove the plug from the drain in the bevel gear case I
92. on 303 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 inspection procedure for the seat belt extension 104270251 Seat Belt Replace SMCS Code 7327 510 Within 3 years of the date of installation or within 5 years of the date of manufacture Caterpillar recommends replacing 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 196 Maintenance Section Steering Charge Filter Replace SEBU8593
93. 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 any remaining pressure 3 Ae g01943757 Illustration 253 Front view of the hydraulic tank 1 Filler cap 2 Pressure vacuum breaker valve 3 Oil level sight gauge 4 Drain plug 5 Press the button on pressure vacuum breaker valve 2 in order to relieve any tank pressure Slowly remove filler cap 1 Illustration 254 g01943758 Top view of the hydraulic tank 3 g01943759 Illustration 255 Left hand inboard 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 Unbolt hydraulic tank access cover 6 A A Illustration 256 g01943760 Cutaway view of interior of hydraulic tank 9 Case drain return bypass valve and screen assembly 10 Implement return screen 8 Remove implement return screen 10 Clean the screen with clean nonflammable solvent 9 Remove case drain return bypass valve and screen assembly 9 A spring and valve mec
94. ool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates SEBU8593 191 Maintenance Section Radiator Core Clean Obtain the sample of the power train 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 a consistent trend of data must be established In order to establish a pertinent history of data perform consistent oil samplings that are evenly spaced 1 Start the engine Park the machine on level ground Engage the parking brake 2 Lower all implements to the ground After lowering all implements to the ground deactivate the implement controls with the implement lockout switch 3 Locate the power train oil sampling valve The sampling valve is located below the fuel tank at the rear of the machine on the left hand power train oil filter base NW Gen Gay Illustration 293 g02507837 Power train oil sampling valve 4 Remove the protective cap from the sampling valve 5 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 6 After you take a sample remove the cap with the tube and the probe from the bottle Properly dis
95. ould 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 102092057 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 224 g00941949 1 Start the engine Run the engine at low idle Illustration 225 g00038585 SEBU8593 161 Maintenance Section Equalizer Bar Center Pin Measure 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
96. pic Operation and Maintenance Manual Capacities Refill in this manual Clean oil filler cap 4 and install the oil filler cap 9 To ensure that the correct amount of oil was added always measure the oil level with the engine oil level gauge 5 10 Remove engine oil level gauge 5 Examine the oil level gauge in order to determine the engine oil level The gauge can be read on both sides One side is marked ENGINE STOPPED The other side is marked ENGINE LOW IDLE 160 Maintenance Section Engine Valve Lash Check Adjust SEBU8593 g02486238 Illustration 223 1 Engine high speed oil change connection fitting if equipped 2 Power train high speed oil change connection fitting if equipped reference only Engine high speed oil change connection fitting if equipped 1 can be used with additional equipment to change the engine oil The filter will still need changed as described previously 102092049 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 c
97. pose of the cap with the tube and the probe Install the sealing cap that is provided with 169 8373 Fluid Sampling Bottle 7 Replace the protective cap on the oil sampling valve 8 Stop the engine For additional information about transmission system oil see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 102612642 Radiator Core Clean SMCS Code 1353 070 1805 070 1810 070 Illustration 294 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 104352773 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 192 Maintenance Section Recoil Spring Compartment Oil Level Check SEBU8593 Illustration 295 g02508236 Coolant filler cap 1 The coolant filler cap is located beneath the access cover on top of the hood forward of the engine air precleaner Open the cover on top of the hood to access the filler c
98. r to the Service Manual Engine Disassembly and Assembly for the necessary replacement procedure Caterpillar recommends checking the engine mounts for deterioration This will prevent excessive engine vibration that is caused from improper mounting SEBU8593 153 Maintenance Section Engine Mounts and Equalizer Bar Inspect 104045624 Engine Mounts and Equalizer Bar Inspect SMCS Code 1152 040 7206 040 Engine Mounts Caterpillar recommends checking the engine mounts for deterioration This recommendation 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 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 209 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
99. red to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat 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 a consistent trend of data is important to establishing a pertinent data history 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 SEBU8593 165 Maintenance Section Final Drive Seal Guard Inspect Clean Illustration 235 g01394195 2 Position one final drive so that oil level mark 2 is horizontal with the oil filler plug 1 3 Remove oil filler plug 4 The oil level should be at the bottom of the filler plug opening 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
100. rm 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 j Illustration 212 g01108801 1 Clean the areas that are around the center pin and equalizer bar im t A GQ LY Q gt lo q o 0 Illustration 213 g01108803 2 Put a 55 ton hydraulic jack in position under the main frame as shown Illustration 214 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 SEBU8593 155 Maintenance Section Engine Oil Level Check 4 Jack up the front 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 215 g01108806 The equalizer bar pads are under the front guard which is underneath the machine Inspect the equalizer b
101. ry replace the plug seal 4 Clean the drain plug and install the drain plug 202 Maintenance Section Winch Wire Rope Install SEBU8593 Illustration 324 g00722361 5 Remove the oil level plug 6 Fill the oil compartment until oil is visible at the bottom of the opening for the oil level plug See Operation and Maintenance Manual Refill Capacities g00722366 Illustration 325 7 Clean the vent plug that is in the filler plug Use a clean nonflammable solvent 8 Install the oil filler plug 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 the oil level plug 10 Install the oil level plug 102094238 Winch Wire Rope Install If Equipped SMCS Code 5154 012 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 ferrule The ferrule is placed into a socket on the drum Use the following table to order the cable Table 28 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 326 g01076208 1 Put the cable
102. s 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 opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Illustration 219 g02483077 Crankcase drain access cover on left hand side of bottom engine guard _ Remove two bolts in order to remove the crankcase drain access cover The drain access cover is located on the le
103. s without a fast fill fuel adapter Use the same procedure for changing the filter in the two systems 104342173 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 opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat products Dispose of all fluids according to local regulations and mandates Illustration 250 g02498496 SEBU8593 173 Maintenance Section Fuses and Circuit Breakers Replace Reset The drain valve is under the fuel tank at the rear of the machine 1 Open the drain valve Allow the water and the sediment to drain into a suitable container 2 Close the drain valve 104357075 Fuses and Circuit Breakers Replace Reset SMCS Code 1417 510 1420 529 1420 Fuses These fuses protect the electrical system from damage that is caused by overloaded circuits Replace a fuse if the element separates The circuit should be checked and repaired if the element separates with a new fuse The fuses are in the operator compartment NOTICE Replace the fuses with the same type
104. stration 319 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 102775471 Winch Fairlead Rollers Lubricate SMCS Code 5163 086 If equipped SEBU8593 201 Maintenance Section Winch Oil Level Check Illustration 320 g01387081 Lubricate the five fittings Use MPGM Grease 102775441 Winch Oil Level Check SMCS Code 5163 535 FLV If equipped PA140VS Illustration 321 g01387065 1 Remove the 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 around the covers and around the hoses Repair any oil leaks 101369498 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 PA59HS Illustration 322 1 Remove the oil filler plug g00722380 Illustration 323 2 Remove the drain plug on the bottom of the winch Allow the oil to drain into a suitable container 3 Inspect the plug seal If necessa
105. t 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 schedule will prevent debris accumulation in the cores and future plugging Access to the cores can be made through the engine access doors from the rear of the cores Access from this direction results in blowing air in the same direction as the normal air flow through the fan All machine 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 mode allows prolonged periods of the reverse flow while the machine is parked Next slots 3 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 SEBU8593 143 Maintenance Section Cooler Cores and A C Condenser Clean 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 cleaning may require opening radiator doors and removing debris guards for access Incomplete cleaning with water may cause remaining debris to harden in place Use lig
106. taining fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat 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 the parking brake and stop the engine 5 Illustration 257 g02500237 Hydraulic oil tank located above right hand fender 1 Filler cap 2 Pressure vacuum breaker valve 3 Oil level sight gauge 4 Drain valve 5 Pipe plug 1 Press the button on pressure vacuum breaker valve 2 in order to relieve any tank pressure Slowly remove filler cap 1 2 Remove pipe plug 5 that is screwed into drain valve 4 Hold the drain valve with a wrench if necessary to keep the valve from turning while removing the pipe plug 3 Install a 12 7 mm 0 5 inch drain pipe into the drain valve The pipe must have 1 2 14 NPTF threads Clamp a hose to the pipe in order to direct the oil into a suitable container 4 Open the drain valve by turning the square stem that is on top of the valve The notch found in the stem is a reference that is aligned with the internal opening of the valve ball Allow the oil to drain into a suitable container 5 Remove the filler strainer inside the fil
107. tem to fully prime NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again 3 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 4 The fuel system will need to be primed when the fuel filters are replaced or fuel has been lost in the fuel supply system 104339009 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 opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Dealer Ser vice Tool Catalog for tools and supplies suitable to collect and contain fluids on Cat 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
108. the Operation and Maintenance Manual Operator Controls and refer to section Enhanced Auto Shift EAS for more information 2 Start the engine 3 Raise all attachments Illustration 181 g02281993 4 Depress the service brake pedal 5 Release the parking brake 6 While the service brake pedal is depressed move the directional control to the SECOND SPEED FORWARD position 7 Gradually increase the engine speed to full load speed The machine should not move 8 Move the directional control to the NEUTRAL position 9 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 necessary repair the service brake before returning the machine to operation SEBU8593 139 Maintenance Section Bulldozer Tilt Brace and Tilt Cylinders Lubricate 102229253 Bulldozer Tilt Brace and Tilt Cylinders Lubricate SMCS Code 6050 086 Lubricate the two fittings with CAT multipurpose type grease with molybdenum disulfide MPGM Illustration 182 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
109. the drain stream method from oil drain plug 3 to obtain a sample of the final drive oil A stream of dirty oil from the bottom of the compartment will contaminate the sample Likewise never dip an oil sample from an oil container or pour a sample from a used filter 5 Wipe the magnet in order to clean the plug 6 Install oil filler plug 7 Repeat Step 2 to Step 6 in order to sample the oil level in the other final drive 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 102211034 Final Drive Seal Guard Inspect Clean If Equipped SMCS Code 4052 040 4052 070 Note The final drive seal guards may need to be inspected more frequently than the standard 500 service hour interval when the machine is operated in very severe applications Adjust the interval if necessary Illustration 236 g00941487 1 Guard 2 Inspection cover 1 Remove the inspection cover 2 on the guard 1 2 Inspect the condition of the final drive underneath the guard
110. the filter elements Properly discard the filter elements 3 Clean the filter element housings and clean the filter bases 3 with a clean cloth Illustration 278 g02505876 7 Locate power train oil level gauge 5 The power train oil level gauge is located behind the angled access cover that is rearward of the left hand engine access door BR I I OT SIC ee BOE RERE EREE OE EET Illustration 279 g01423532 8 Maintain the oil level within operating range X between the ADD mark and the FULL mark on the oil level gauge a When the engine is stopped and the oil is cold ambient temperature maintain the oil level on the ENGINE STOPPED COLD OIL side of the oil level gauge This method should be used as reference only before the engine is started b When the engine is running and the oil is hot operating temperature maintain the oil level on the ENGINE LOW IDLE HOT OIL side of the oil level gauge This procedure is the only accurate way to check the oil level 186 Maintenance Section Power Train Scavenge Screen Clean SEBU8593 Note When you are operating the machine on severe slopes the quantity of oil in the power train can be increased up to 10 percent When you are operating with the increased oil quantity prolonged operation in some machines can cause high power train oil temperatures After the work on the severe slopes has been completed drain the excessive oil
111. umption 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 158 Maintenance Section Engine Oil and Filter Change SEBU8593 This program consists of three oil change intervals of 500 hours Oil sampling and analysis are 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 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 25 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 are done during each interval The analysi
112. y e Recycling facility 104355655 Belt Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 This engine is equipped with a serpentine belt that drives the alternator and the air conditioner compressor The belt tightener on this engine automatically adjusts the serpentine 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 Turn the battery disconnect switch to the OFF position 3 Open both the right hand and left hand engine access doors 3 ale 4 A A oe RASS Illustration 180 g02510641 Engine front left view Belt tensioner Idler pulley grooved Idler pulleys smooth Alternator pulley Air conditioner compressor pulley Serpentine belt Crankshaft drive pulley hidden from view behind crankshaft damper 1 2 3 4 5 6 7 4 Inspect the condition of serpentine belt 6 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 138 Maintenance Section Braking System Test SEBU8593 5 Close both the right hand and left hand engine access doors 6 Turn the battery disconnect switch to the ON position Replace 1 Park the machine on level ground Lower the dozer bla

Maintenance Intervals - Safety

Contents

Download Pdf Manuals

Related Search

Related Contents