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MAINTENANCE INTERVALS

Operation and Maintenance


Manual Excerpt

® ®
© 2010 Caterpillar
All Rights Reserved
SEBU8252-01
August 2007

Operation and
Maintenance
Manual
D7G and D7G Series II Track-Type
Tractors
7MB5000-Up (Machine)
X7C100-Up (Machine)
C7G1000-Up (Machine)
66 SEBU8252-01
Maintenance Section
Maintenance Interval Schedule

i02797093 Hydraulic System Oil Level - Check ..................... 94


Seat Belt - Inspect ................................................ 98
Maintenance Interval Schedule Transmission Oil Level - Check .......................... 106
SMCS Code: 7000 Every 50 Service Hours or Weekly
Ensure that all safety information, warnings, and Bulldozer Cylinder Support Bearings - Lubricate .. 70
instructions are read and understood before any Ripper Linkage and Cylinder Bearings -
operation or any maintenance procedures are Lubricate ............................................................. 97
performed. Sprocket Hub Bearings - Inspect .......................... 99
Track Pins - Inspect ............................................ 102
The user is responsible for the performance of Track Roller Frame Bearings - Lubricate ............ 102
maintenance, including all adjustments, the use of
proper lubricants, fluids, filters, and the replacement Every 100 Service Hours or 2 Weeks
of components due to normal wear and aging. Failure
to adhere to proper maintenance intervals and Hydraulic Control Linkage - Lubricate ................... 92
procedures may result in diminished performance of
the product and/or accelerated wear of components. Every 250 Service Hours or Monthly

Use mileage, fuel consumption, service hours, or Belts - Inspect/Adjust/Replace .............................. 69


calendar time, WHICH EVER OCCURS FIRST, Bulldozer Tilt Brace - Lubricate ............................. 70
in order to determine the maintenance intervals. Fan Drive Bearing - Lubricate ............................... 84
Products that operate in severe operating conditions Final Drive Oil Level - Check ................................ 85
may require more frequent maintenance. Track - Check/Adjust ........................................... 100

Note: Before each consecutive interval is performed, Every 250 Service Hours or 3 Months
all maintenance from the previous interval must be
Engine Oil and Filter - Change ............................. 81
performed.

When Required Initial 500 Hours (for New Systems, Refilled


Systems, and Converted Systems)
Battery - Recycle .................................................. 68
Battery, Battery Cable or Battery Disconnect Switch - Cooling System Coolant Sample (Level 2) -
Replace ............................................................... 68 Obtain ................................................................. 76
Condenser (Refrigerant) - Clean .......................... 71
Cutting Edges and End Bits - Inspect/Replace ..... 77 Every 500 Service Hours
Engine Air Filter Primary Element - Clean/
Cooling System Coolant Sample (Level 1) -
Replace ............................................................... 78
Obtain ................................................................. 75
Engine Air Filter Secondary Element - Replace ... 79
Final Drive Oil Sample - Obtain ............................ 85
Engine Air Precleaner - Clean .............................. 80
Transmission Oil Sample - Obtain ...................... 107
Ether Starting Aid Cylinder - Replace ................... 83
Fuel System - Prime ............................................. 86
Fuses and Circuit Breakers - Replace/Reset ........ 90
Every 500 Service Hours or 3 Months
Oil Filter - Inspect .................................................. 96 Engine Crankcase Breather - Clean ..................... 80
Radiator Core - Clean ........................................... 96 Equalizer Bar Pads - Inspect/Replace .................. 83
Radiator Pressure Cap - Clean/Replace .............. 96 Fuel System Primary Filter - Clean/Replace ......... 87
Ripper Tip and Shank Protector - Inspect/ Fuel System Secondary Filter - Replace .............. 88
Replace ............................................................... 97 Fuel Tank Cap and Strainer - Clean ..................... 89
Window Washer Reservoir - Fill .......................... 108 Hydraulic System Oil Filter - Replace ................... 93
Window Wipers - Inspect/Replace ...................... 109 Hydraulic System Oil Sample - Obtain ................. 94
Windows - Clean ................................................. 109 Sprocket Hub Bearings - Inspect .......................... 99
Transmission Oil Filter - Replace ........................ 106
Every 10 Service Hours or Daily
Backup Alarm - Test .............................................. 68
Every 1000 Service Hours
Brakes, Indicators and Gauges - Test ................... 69 Battery - Inspect .................................................... 68
Cooling System Coolant Level - Check ................ 74
Engine Oil Level - Check ...................................... 80 Every 1000 Service Hours or 6 Months
Fuel System Primary Filter (Water Separator) -
Drain ................................................................... 86 Transmission Magnetic Screen - Clean .............. 103
Fuel Tank Water and Sediment - Drain ................. 89 Transmission Oil - Change ................................. 104
Horn - Test ............................................................ 91
SEBU8252-01 67
Maintenance Section
Maintenance Interval Schedule

Every 2000 Service Hours or 1 Year


Engine Valve Lash - Check ................................... 82
Engine Valve Rotators - Inspect ........................... 82
Final Drive Oil - Change ....................................... 84
Hydraulic System Oil - Change ............................. 92
Sprocket Hub Bearings - Adjust ............................ 99

Every Year
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 76

Every 3 Years After Date of Installation or


Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................... 98

Every 4000 Service Hours or 2 Years


Cooling System Water Temperature Regulator -
Clean/Replace .................................................... 77

Every 6000 Service Hours or 3 Years


Cooling System Coolant Extender (ELC) - Add .... 73

Every 12 000 Service Hours or 6 Years


Cooling System Coolant (ELC) - Change ............. 71
68 SEBU8252-01
Maintenance Section
Backup Alarm - Test

i02564752 3. Close the battery access cover.


Backup Alarm - Test
i00993589
SMCS Code: 7406-081
Battery - Recycle
SMCS Code: 1401-561

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the following


locations:

• A battery supplier
• An authorized battery collection facility
• Recycling facility
g01283957
Illustration 82
i00760485

In order to test the alarm for proper functioning, turn Battery, Battery Cable or
engine start switch (1) to the ON position.
Battery Disconnect Switch -
Apply both brakes (2). Disengage parking brake (3). Replace
Move transmission control lever (4) to the REVERSE
position. SMCS Code: 1401-510; 1402-510; 1411-510
The backup alarm should sound immediately. The 1. Turn the engine start switch key to the OFF
alarm alerts the personnel behind the machine that position. Turn all of the switches to the OFF
the machine is backing up. The backup alarm will position.
continue to sound until transmission control lever
(4) is moved to the NEUTRAL position or to the 2. Turn the battery disconnect switch to the OFF
FORWARD position. position. Remove the key.
The backup alarm is at the rear of the machine. The 3. Disconnect the battery cable at the battery
nonadjustable backup alarm is set at the appropriate disconnect switch. The battery disconnect switch
sound level when the machine is shipped from the is connected to the machine frame.
factory.
4. Disconnect the negative battery cable at the
i02486605
battery.

Battery - Inspect 5. Make necessary repairs or replace the battery.

SMCS Code: 1401-040 6. Connect the negative battery cable at the battery.

Tighten the battery retainers on all batteries at every 7. Connect the battery cable at the battery disconnect
1000 hour interval. switch.

Perform the following procedures at every 1000 hour 8. Install the key and turn the battery disconnect
interval. Check these areas more often, if necessary. switch to the ON position.

1. Open the battery access cover. The battery access


cover is located on the left side or right side of the
machine next to the operator’s compartment.

2. Clean the top of the batteries with a clean


cloth. Keep the terminals clean and coated with
petroleum jelly. Install the terminal covers after
you coat the terminals.
SEBU8252-01 69
Maintenance Section
Belts - Inspect/Adjust/Replace

i02578326

Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510

Inspect
1. Open the engine access doors on both sides of
the machine, as needed.

Note: Even if only one belt is worn or damaged,


replace the belts in sets.

2. Inspect the condition of the fan drive belt, the


alternator and water pump belt, and the air
conditioning compressor belt. The belts should
deflect 14 to 20 mm (.56 to .81 inch) under 110 N
(25 lb) of force. Use a 144-0235 Belt Tension
Gauge in order to measure the tension.
g01291786
Adjust/Replace Illustration 84
Air conditioning compressor belt
(A) Front view
(B) Rear view

1. Loosen bolts (1).

2. Turn adjusting nut (2) until the correct belt


tension is reached. To achieve the correct belt
adjustment, move the compressor inward or move
the compressor outward, as required.

3. Tighten bolts (1). Tighten adjusting nut (2).

4. Close the access doors.

Illustration 83
g01291778 Note: Use the same procedure in order to replace
Alternator and fan drive
the belts.

1. Loosen bolts (1). Note: If new belts are installed, check the belt
adjustment again after 30 minutes of engine
2. Loosen adjusting nuts (2). To achieve the correct operation.
belt adjustment, move the alternator inward or
move the alternator outward, as required. Tighten i02564751
adjusting nuts (2).
Brakes, Indicators and Gauges
3. Tighten bolts (1).
- Test
SMCS Code: 4100-081; 7450-081

Before you operate the machine, perform the


following checks and make any necessary repairs.
70 SEBU8252-01
Maintenance Section
Bulldozer Cylinder Support Bearings - Lubricate

i01283379

Bulldozer Cylinder Support


Bearings - Lubricate
(If Equipped)
SMCS Code: 6050-086

g01283956
Illustration 85

• Check for the following damage: broken lenses


on the gauges, broken indicator lights, broken
switches, and other broken components in the cab.

• Start the engine.


g00680367
• Check the monitor panel for proper operation. See Illustration 86
Operation and Maintenance Manual, “Monitoring
System”. 1. Lubricate the three fittings on the left side of the
machine.
• Check for oil leaks. Repair any oil leaks around the
covers or around the hoses. 2. Lubricate the three fittings on the right side of the
machine.
• Look for inoperative gauges.
i02578341
• Turn on all machine lights. Check for proper
operation. Bulldozer Tilt Brace - Lubricate
• Sound the forward horn. (If Equipped)
• Move the machine forward and test the service SMCS Code: 6050-086
brakes. If the service brakes malfunction, consult
your Caterpillar dealer for repairs.

• Engage the parking brake. Move the machine


forward in order to test the parking brake. If the
parking brake malfunctions, consult your Caterpillar
dealer for repairs.

g01291787
Illustration 87
SEBU8252-01 71
Maintenance Section
Condenser (Refrigerant) - Clean

Lubricate the grease fittings. Lubricate two fittings on i02575986


each tilt brace, as needed.
Cooling System Coolant (ELC)
i02573839
- Change
Condenser (Refrigerant) - SMCS Code: 1395-044
Clean For information about adding an extender to your
cooling system, see the Topic “Cooling System
SMCS Code: 1805-070 Coolant Extender (ELC) - Add” in this manual or
consult your Caterpillar dealer.
NOTICE
If excessively dirty, clean condenser with a brush. To
NOTICE
prevent damage or bending of the fins, do not use a
Care must be taken to ensure that fluids are contained
stiff brush.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
Repair the fins if found defective.
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.

To Drain the Cooling System


The filler cap is located inside the radiator access
door on the top of the engine enclosure.

g01289388
Illustration 88

1. Remove the cover for the condenser.

2. Inspect the condenser for debris. Clean the


condenser, if necessary.

3. Use clean water to wash all of the dust and dirt


from the condenser.

4. Install the cover for the condenser.

g01290126
Illustration 89
72 SEBU8252-01
Maintenance Section
Cooling System Coolant (ELC) - Change

3. Route the drain hose through the left hole in the


radiator guard in order to drain the coolant. Direct
the drain hose into a suitable container.

g01290745
Illustration 90
Rear view of radiator

g01017961
Illustration 92

4. Open the drain valve. Allow the coolant to drain


Personal injury can result from hot coolant, steam
into a suitable container.
and alkali.
5. Flush the system with water. Flush the system
At operating temperature, engine coolant is hot
until the draining water is clear.
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
Note: If the cooling system is already using ELC,
steam. Any contact can cause severe burns.
cleaning agents are not required to be used at
the specified coolant change interval. Cleaning
Remove filler cap slowly to relieve pressure only
agents are only required if the system has been
when engine is stopped and radiator cap is cool
contaminated by the addition of some other type of
enough to touch with your bare hand.
coolant or by cooling system damage. Clean water is
the only cleaning agent that is required when ELC is
Cooling System Conditioner contains alkali. Avoid
drained from the cooling system.
contact with skin and eyes.
Note: If you change to an ELC from another type of
1. Slowly loosen filler cap (1) in order to relieve coolant, use a Caterpillar cleaning agent to flush the
system pressure. Remove the filler cap. cooling system. After you drain the cooling system,
thoroughly flush the cooling system with clean water.
2. The drain valve for coolant is located under the left All of the cleaning agent must be removed from
side of the radiator. Open the left engine access the cooling system..
door in order to properly access radiator drain
valve (2). 6. Close the radiator drain valve completely.

7. Replace the drain hose inside the radiator guard.

Filling The Cooling System


1. Add the ELC solution. See the following topics in
this publication:

• Capacities (Refill)
Note: Caterpillar antifreeze contains additive. If
you are using Caterpillar antifreeze, do not add the
supplemental coolant additive at this time. Also,
do not change the supplemental coolant additive
g01290751 element at this time.
Illustration 91
Front view of radiator guard
SEBU8252-01 73
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

2. Start the engine. Run the engine without the filler i02578612
cap until the thermostat opens and the coolant
level stabilizes. Cooling System Coolant
Extender (ELC) - Add
3. Maintain the coolant level at 13 mm (0.5 inch)
from the bottom of the filler tube. Add coolant to SMCS Code: 1395-538
the filler tube, if necessary.
NOTICE
4. If the gasket is damaged, replace the filler cap.
Care must be taken to ensure that fluids are contained
Install the filler cap.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
5. Stop the engine.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar


Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and


mandates.

Table 6
RECOMMENDED AMOUNT OF EXTENDER BY
COOLING SYSTEM CAPACITY
g01117259
Illustration 93
Recommended Amount
Cooling System Capacity
of Extender
6. Clean the radiator cores with compressed air. You
may need to use water in order to remove debris. 22 to 30 L (6 to 8 US gal) 0.57 L (0.60 qt)
30 to 38 L (8 to 10 US gal) 0.71 L (0.75 qt)
7. Close the engine access door.
38 to 49 L (10 to 13 US gal) 0.95 L (1 qt)
For additional information about the cooling
49 to 64 L (13 to 17 US gal) 1.18 L (1.25 qt)
system coolant, see Operation and Maintenance
Manual, SEBU6250, “Caterpillar Machine Fluids 65 to 83 L (17 to 22 US gal) 1.60 L (54 oz)
Recommendations”, “Cat Extended Life Coolant
(ELC)” or consult your Caterpillar dealer.
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.
74 SEBU8252-01
Maintenance Section
Cooling System Coolant Level - Check

i02575971

Cooling System Coolant Level


- Check
SMCS Code: 1353-535-FLV; 1395-535-FLV

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.

g01290126
Illustration 94

1. The filler cap is located on the top of the engine


enclosure. Slowly loosen the filler cap in order to
relieve the pressure. Remove the cap.

2. Add the proper amount of ELC Extender. Add


ELC (Extended Life Coolant). Drain some coolant
from the radiator into a suitable container in order
to allow space for the extra ELC.

Reference: See “Capacities (Refill)” in this


publication for more information on system
capacity.
g01290126
Illustration 95
Note: Always discard drained fluids according to
local regulations. 1. Open the radiator access cover on top of the
engine enclosure.
3. Start the engine. Run the engine without the filler
cap until the thermostat opens and the coolant 2. Remove the cooling system pressure cap slowly
level stabilizes. Check for leaks. in order to relieve the pressure.
4. Check the coolant level. If necessary, add 3. Maintain the coolant level at 13 mm (0.5 inch)
premixed coolant in order to correct the coolant from the bottom of the filler pipe. If it is necessary
level. to add coolant daily, check the system for leaks.
5. Inspect the filler cap gasket. Replace the filler cap 4. Install the cooling system pressure cap. Close the
if the gasket is damaged. radiator access cover.
6. Install the filler cap. 5. Inspect the radiator core for debris. Clean the
radiator core, if necessary.

Reference: See “Radiator Core - Clean” in the


Maintenance Section of this publication for more
information.
SEBU8252-01 75
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain

i02564679 2. The cooling system pressure cap (1) is located


on the top of the radiator. Remove the cooling
Cooling System Coolant system pressure cap slowly in order to relieve
Sample (Level 1) - Obtain system pressure.

SMCS Code: 1350-008; 1395-008; 7542 3. Obtain the coolant sample from radiator filler pipe
(2). Collect the sample into the proper sampling
Note: It is not necessary to obtain a Coolant bottle.
Sample (Level 1) if the cooling system is filled
with Cat ELC (Extended Life Coolant). Cooling Note: Always discard drained fluids according to
systems that are filled with Cat ELC should have local regulations.
a Coolant Sample (Level 2) that is obtained at
the recommended interval that is stated in the Obtain the sample of the coolant as close as possible
Maintenance Interval Schedule. to the recommended sampling interval. In order
to receive the full effect of S·O·S analysis, you
Note: Obtain a Coolant Sample (Level 1) if the must establish a consistent trend of data. In order
cooling system is filled with any other coolant to establish a pertinent history of data, perform
instead of Cat ELC. This includes the following consistent samplings that are evenly spaced.
types of coolants. Supplies for collecting samples can be obtained from
your Caterpillar dealer.
• Commercial long life coolants that meet the
Caterpillar Engine Coolant Specification -1 Use the following guidelines for proper sampling of
(Caterpillar “EC−1”) the coolant:

• Cat Diesel Engine Antifreeze/Coolant (DEAC) • Complete the information on the label for the
sampling bottle before you begin to take the
• Commercial heavy-duty antifreeze/coolant samples.

• Keep the unused sampling bottles stored in plastic


NOTICE bags.
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling. • Obtain coolant samples directly from the coolant
Using the same pump for both types of samples may sample port. You should not obtain the samples
contaminate the samples that are being drawn. This from any other location.
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both • Keep the lids on empty sampling bottles until you
dealers and customers. are ready to collect the sample.

Note: Level 1 results may indicate a need for • Place the sample in the mailing tube immediately
Level 2 Analysis. after obtaining the sample in order to avoid
contamination.

• Never collect samples from expansion bottles.


• Never collect samples from the drain for a system.
4. Maintain the coolant level at 13 mm (0.5 inch)
from the bottom of the filler pipe.

5. Install cooling system pressure cap (1) onto


radiator filler pipe (2). Close the radiator access
cover on top of the engine enclosure.

Submit the sample for Level 1 analysis.


g01283935
Illustration 96 For additional information about coolant analysis, see
Special Publication, SEBU6250, “Caterpillar Machine
1. Open the radiator access cover on top of the Fluids Recommendations” or consult your Caterpillar
engine enclosure. dealer.
76 SEBU8252-01
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain

i02564704 Note: Always discard drained fluids according to


local regulations.
Cooling System Coolant
Sample (Level 2) - Obtain Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order
SMCS Code: 1350-008; 1395-008; 7542 to receive the full effect of S·O·S analysis, you
must establish a consistent trend of data. In order
to establish a pertinent history of data, perform
NOTICE consistent samplings that are evenly spaced.
Always use a designated pump for oil sampling, and Supplies for collecting samples can be obtained from
use a separate designated pump for coolant sampling. your Caterpillar dealer.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This Use the following guidelines for proper sampling of
contaminate may cause a false analysis and an incor- the coolant:
rect interpretation that could lead to concerns by both
dealers and customers.
• Complete the information on the label for the
sampling bottle before you begin to take the
NOTICE samples.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- • Keep the unused sampling bottles stored in plastic
ing, adjusting and repair of the product. Be prepared to bags.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- • Obtain coolant samples directly from the coolant
nent containing fluids. sample port. You should not obtain the samples
from any other location.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies • Keep the lids on empty sampling bottles until you
suitable to collect and contain fluids on Caterpillar are ready to collect the sample.
products.
• Place the sample in the mailing tube immediately
Dispose of all fluids according to local regulations and after obtaining the sample in order to avoid
mandates. contamination.

• Never collect samples from expansion bottles.


• Never collect samples from the drain for a system.
4. Maintain the coolant level at 13 mm (0.5 inch)
from the bottom of the filler pipe.

5. Install cooling system pressure cap (1) onto


radiator filler pipe (2). Close the radiator access
cover on top of the engine enclosure.

Submit the sample for Level 2 analysis.

For additional information about coolant analysis, see


Illustration 97
g01283935 Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” or consult your Caterpillar
1. Open the radiator access cover on top of the dealer.
engine enclosure.

2. The cooling system pressure cap (1) is located


on the top of the radiator. Remove the cooling
system pressure cap slowly in order to relieve
system pressure.

3. Obtain the coolant sample from radiator filler pipe


(2). Collect the sample into the proper sampling
bottle.
SEBU8252-01 77
Maintenance Section
Cooling System Water Temperature Regulator - Clean/Replace

i02576000
NOTICE
Cooling System Water Since Caterpillar engines incorporate a shunt design
Temperature Regulator - cooling system, it is mandatory to always operate the
engine with a thermostat.
Clean/Replace
Depending on load, failure to operate with a thermo-
SMCS Code: 1355-070; 1355-510 stat could result in either an overheating or an over-
cooling condition.
Replace the thermostat on a regular basis in order to
reduce the chance of unscheduled downtime and of
problems with the cooling system. NOTICE
If the thermostat is installed incorrectly, it will cause
A new thermostat should be installed after the cooling the engine to overheat.
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 4. Install a new seal in the thermostat housing. Install
that is below the thermostat housing. a new thermostat and a new gasket. Install the
thermostat housing on the engine cylinder head.
NOTICE 5. Install the elbow and the hose. Tighten the hose
Failure to replace the engine’s thermostat on a regu- clamp.
larly scheduled basis could cause severe engine dam-
age. 6. Close the left engine access door (if equipped).

Note: If you are only installing a new thermostat, i02574808


drain the cooling system coolant to a level that is
below the thermostat housing. Cutting Edges and End Bits -
Inspect/Replace
SMCS Code: 6801-040; 6801-510; 6804-040;
6804-510

g01291207
Illustration 98
Rear view

1. Open the left engine access door (if equipped).

2. Remove the bolts from the elbow. Remove the


elbow and the thermostat housing assembly.

3. Remove the gasket, the thermostat, and the seal


from the thermostat housing.
g01289926
Illustration 99

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.
78 SEBU8252-01
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace

2. Remove the bolts. Then remove the cutting edge


and the end bits.

3. Thoroughly clean all contact surfaces.

4. Inspect the opposite side of the cutting edge. If the


opposite side of the cutting edge is not worn, turn
the opposite side of the cutting edge outward and
install the cutting edge.

5. If both sides of the cutting edge are worn, install a


new cutting edge section.

6. Repeat Steps 4 and 5 for the end bits.


g00100510
7. Install all bolts and tighten the bolts to the specified Illustration 101
torque.
3. Remove the primary filter element from the air
Reference: For more information, refer cleaner housing.
to Specifications, SENR3130, “Torque
Specifications”.

8. Raise the bulldozer blade and remove the


blocking. Lower the bulldozer blade to the ground.

9. After you operate the machine for a few hours,


check all bolts for the proper torque.

i02577718

Engine Air Filter Primary


Element - Clean/Replace
g00039201
SMCS Code: 1051-070; 1051-510-PY; 1054-070-PY; Illustration 102
1054-510-PY
4. Clean the inside of the air cleaner housing.
1. Open the left engine access door (if equipped).
5. Inspect the primary element. If the pleats, the
gaskets, or the seals are damaged, discard the
element. Replace a damaged primary element
with a clean primary element.

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

Make sure the cleaned filter elements are completely


dry before installing into the filter housing. Water re-
maining in the elements can cause false indications
of contamination in Scheduled Oil Sampling test re-
g01291252
sults.
Illustration 100

2. Remove the air cleaner cover. 6. If the primary element is not damaged, clean the
primary element.

The filter elements can be cleaned by using the


following methods:

• Pressure air
SEBU8252-01 79
Maintenance Section
Engine Air Filter Secondary Element - Replace

• Pressure water i01454983

• Detergent washing Engine Air Filter Secondary


Element - Replace
When you use pressure air, the maximum air
pressure is 205 kPa (30 psi). When you use SMCS Code: 1051-510-SE; 1054-510-SE
pressure water, the maximum water pressure is
280 kPa (40 psi).
NOTICE
Always replace the secondary filter element. Never
attempt to reuse it by cleaning.

The secondary filter element should be replaced at the


time the primary element is serviced for the third time.

The secondary filter element should also be replaced


if the yellow piston in the filter element indicator en-
ters the red zone after installation of a clean primary
element, or if the exhaust smoke is still black.

NOTICE
The filter should be kept in service for no longer than
g00039203 one year.
Illustration 103

7. When you clean the inside pleats and the outside NOTICE
pleats, direct the air along the pleats or direct the Always leave the secondary filter element in place
water along the pleats. while you clean the air cleaner housing.
The element can be washed in a solution that
consists of warm water and of nonsudsing 1. Open the engine access door, if equipped.
household detergent. Fully rinse the pleats. Allow
the filter to air dry completely. 2. Remove the air cleaner housing cover.

8. Inspect the filter elements after you clean the filter 3. Remove the primary filter element. Refer to
elements. Do not use a filter if the pleats, the Operation and Maintenance Manual, “Engine Air
gaskets or the seals are damaged. Filter Primary Element - Clean/Replace”.

9. Cover the clean filter elements. Store the elements 4. Clean the inside of the air cleaner housing.
in a clean, dry location.

A primary element may be cleaned for a maximum


of six times. Also replace the primary element if
the primary element has been used for one year.

10. Install a clean primary filter element.

11. Clean the cover and install the cover.

12. Close the access door (if equipped).

13. Reset filter element indicator (1) that is located


in the cab (if equipped).
g00470240
Start the engine. If the yellow piston in the filter Illustration 104
element indicator moves into the red zone, install
a new primary filter element. Also if the exhaust 5. Remove the secondary filter element. Pull out in
smoke is black, install a new primary filter element. order to remove the element.
80 SEBU8252-01
Maintenance Section
Engine Air Precleaner - Clean

6. Install a new secondary filter element. Push


the element firmly in order to properly seat the
element. Write the date on the element, if the
element is replaced.

7. Install the primary filter element and the air cleaner


housing cover.

8. Close the engine access door, if equipped.

i02575964

Engine Air Precleaner - Clean


SMCS Code: 1050-070 Illustration 106
g01290701

Right side view

1. Loosen breather outlet hose clamp (2) and remove


the hose from the breather cover.

2. Loosen the breather retaining bolt (1) and remove


breather (3).

3. Inspect the breather seal. Replace the breather


seal if the breather is damaged.

4. Wash the breather in clean, nonflammable solvent.

5. Use pressure air to dry.

6. Install clean breather (3).

7. Tighten breather retaining bolt (2) to a torque of


14 ± 3 N·m (10 ± 2 lb ft).

8. Install the hose to breather (3) and tighten hose


g01290736
Illustration 105 clamp (2).

1. Inspect the cup visually. The cup should be


emptied whenever dirt reaches the indicator mark. i02577746

2. Loosen the wing nut on the top of the precleaner. Engine Oil Level - Check
Remove the cover and the cup. Empty and clean
the cup. Clean the cover. SMCS Code: 1302-535-FLV; 1326-535-FLV

3. Install the cup and the cover. Finger tighten the


wing nut. Do not use a tool.
Hot oil and components can cause personal in-
jury.
i02575874

Engine Crankcase Breather - Do not allow hot oil or components to contact


skin.
Clean
SMCS Code: 1317-070 NOTICE
Do not under fill or overfill engine crankcase with oil.
The engine crankcase breather is located on top of Either condition can cause engine damage.
the front side of the engine.
1. Open the engine access door on the left side of
the machine (if equipped).
SEBU8252-01 81
Maintenance Section
Engine Oil and Filter - Change

i02577765

Engine Oil and Filter - Change


SMCS Code: 1308; 1318-510

g01283493
Illustration 108
g01291293
Illustration 107 1. Remove the crankcase drain valve access cover,
which is in the crankcase guard.
2. Check dipstick (2) while the engine is running at
LOW IDLE WITH WARM OIL. The oil should be
at operating temperature. Maintain the oil level
between the “ADD” mark and the “FULL” mark.
This is the only accurate way to check the oil level.

Check dipstick (2) with the “ENGINE STOPPED


AND COLD OIL”. The oil should be cold. Maintain
the oil level in the “SAFE STARTING RANGE”.
This method should be used as reference only,
before the engine is started.

Note: When you operate the machine on severe


slopes, the oil level in the engine crankcase must
be at the “FULL” mark on the “LOW IDLE” side of
dipstick (2). Illustration 109
g01283497

3. Remove oil filler cap (1). If necessary, add oil. 2. Remove the drain plug. Then, open drain valve
(1). Allow the oil to drain into a suitable container.
4. Clean the oil filler cap and install the oil filler cap.
3. Close the drain valve after all of the oil has
5. Close the engine access door (if equipped). drained. Install the drain plug.

4. Install the crankcase drain valve access cover.

5. Open the left engine access door (if equipped).


82 SEBU8252-01
Maintenance Section
Engine Valve Lash - Check

i02562935

Engine Valve Lash - Check


SMCS Code: 1102-535; 1209-535

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.
g01291352
Illustration 110
NOTICE
6. Remove the used crankcase oil filter element. Operation of Caterpillar engines with improper valve
Make sure that all of the old filter seal is removed adjustments will reduce engine efficiency. This re-
from the filter base. duced efficiency could result in excessive fuel usage
and/or shortened engine component life.
7. Apply a thin film of clean engine oil to the new
filter seal.
NOTICE
8. Install the new oil filter elements by hand. Measure the valve clearance with the engine stopped.
To obtain an accurate measurement, allow at least 20
Instructions for the installation of the filters are minutes for the valves to cool to engine cylinder head
printed on the side of each Caterpillar spin-on and engine block temperature.
filter. For non-Caterpillar filters, refer to the
installation instructions that are provided by the Check the valve bridge before setting the valve lash.
supplier of the filter. Ensure that the valve bridge is seated equally on
both valve stems.
9. Remove the oil filler cap. Fill the crankcase with
new oil. See Operation and Maintenance Manual, Refer to your machine’s Service Manual or your
“Capacities (Refill) ”. Clean the oil filler cap and Caterpillar dealer for the complete valve adjustment
install the oil filler cap. procedure.

10. Always measure the oil level with the dipstick in


order to ensure that the correct amount of oil was i02562938
added.
Engine Valve Rotators - Inspect
11. On the dipstick, maintain the oil level between the
SMCS Code: 1109-040
“ADD” mark and “FULL” mark.
Perform the following procedure after you set all the
12. Close the left engine access door.
valve clearances and before you install the valve
cover.

1. Start the engine.

2. Position the governor control lever to the LOW


IDLE position.
SEBU8252-01 83
Maintenance Section
Equalizer Bar Pads - Inspect/Replace

g00679445 g01282952
Illustration 111 Illustration 113

3. Watch the top surface on each valve rotator. The 2. Inspect the rubber pads. Replace the rubber pads
rotator should turn slightly. if the rubber pad is cracked. Replace the rubber
pads if the rubber pad is starting to peel. Install
If a valve fails to rotate, consult your Caterpillar the guards.
dealer.
Consult your Caterpillar dealer for replacements.
i02575870

Equalizer Bar Pads - i02575747

Inspect/Replace Ether Starting Aid Cylinder -


Replace
SMCS Code: 7206-040-JP; 7206-510-JP
(If Equipped)
SMCS Code: 1456-510-CD

The ether starting aid cylinder is located on the left


side of the engine.

g01290699
Illustration 112

1. Remove the guards.

g01290650
Illustration 114

1. Open the left engine access door.


84 SEBU8252-01
Maintenance Section
Fan Drive Bearing - Lubricate

Open the right engine access door.

g01290655
Illustration 115
g00677343
Illustration 117
2. Loosen the cylinder retaining clamp from the
support that is bolted to the cylinder block casting. Lubricate the fitting.
Unscrew and remove empty ether starting aid
cylinder (not shown). Close the right engine access door.
3. Remove the used gasket. Install the new gasket
that is provided with each new ether starting aid i02562747
cylinder.
Final Drive Oil - Change
4. Install the new ether starting aid cylinder. Tighten
the ether starting aid cylinder by hand. Tighten the SMCS Code: 4050-535-FLV
cylinder retaining clamps securely.

5. Close the left engine access door.

i02575744

Fan Drive Bearing - Lubricate


SMCS Code: 1359-086-BD

The fitting is located on the right side of the engine.

g01280809
Illustration 118
Rear view
Some components are removed for clarity.

1. Remove the oil filler plug.

g01290577
Illustration 116
SEBU8252-01 85
Maintenance Section
Final Drive Oil Level - Check

i02558810

Final Drive Oil Sample - Obtain


SMCS Code: 4050-008

Hot oil and hot components can cause personal


injury. Do not allow hot oil or hot components to
contact the skin.

NOTICE
g00679408
Care must be taken to ensure that fluids are contained
Illustration 119 during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
2. Remove the drain plug. Drain the oil in a suitable collect the fluid with suitable containers before open-
container. ing any compartment or disassembling any compo-
nent containing fluids.
3. Install the drain plug.
Refer to Special Publication, NENG2500, “Caterpillar
4. Maintain the oil level to the bottom of the plug. Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
5. Clean the filler plug. Install the filler plug. products.
6. Repeat the procedure for the other final drive. Dispose of all fluids according to local regulations and
mandates.
i02558808

Final Drive Oil Level - Check Obtain the Sample and the Analysis
SMCS Code: 4050-535-FLV In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
analysis at regular scheduled intervals in order
to monitor the condition and the maintenance
requirements of the final drives.

Each oil sample should be taken when the oil is warm


and when the oil is well mixed in order to ensure that
the sample is representative of the oil in the final
drives.

Obtain the S·O·S Sample


To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
g01280809
samples must be clean.
Illustration 120
Rear view
Some components are removed for clarity.

1. Remove the oil filler plug on the inside of the case


and frame.

2. Check the oil level. Oil should be to the bottom


of the filler plug opening. If necessary, add oil to
the final drive.

3. Install the filler plug. Repeat this procedure for the


other final drive.
86 SEBU8252-01
Maintenance Section
Fuel System - Prime

1. Turn the priming pump plunger to the left. This will


unlock the priming pump.

2. Operate the pump until a slight pressure is felt.

3. Turn the priming pump plunger to the right. This


will lock the priming pump.

4. Start the engine. Inspect the fuel priming pump


for leaks.

i02575683

Fuel System Primary Filter


Illustration 121
g01280809
(Water Separator) - Drain
Rear view of the case and frame
Oil sampling SMCS Code: 1263-543

1. Remove the oil filler plug and obtain the oil sample
with a proper suction device. Use a 1U-7683
Suction Gun or use an equivalent pump such as Fuel leaked or spilled onto hot surfaces or elec-
1U-5718 Vacuum Pump to take the oil sample. trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
2. Install the oil filler plug. changing fuel filters or water separator elements.
Clean up fuel spills immediately.
3. Repeat Step 1 to Step 2 in order to sample the oil
in the other final drive.
NOTICE
Refer to Special Publication, PEHP6001 for more Care must be taken to ensure that fluids are contained
information on obtaining a good oil sample. Consult during performance of inspection, maintenance, test-
your Caterpillar dealer for complete information and ing, adjusting and repair of the product. Be prepared to
assistance in establishing an S·O·S program for your collect the fluid with suitable containers before open-
machine. ing any compartment or disassembling any compo-
nent containing fluids.
i02575650
Refer to Special Publication, NENG2500, “Caterpillar
Fuel System - Prime Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
SMCS Code: 1258 products.

The priming pump is located inside the right engine Dispose of all fluids according to local regulations and
access door. mandates.

g01290529
Illustration 122
SEBU8252-01 87
Maintenance Section
Fuel System Primary Filter - Clean/Replace

i02575684

Fuel System Primary Filter -


Clean/Replace
SMCS Code: 1260-070; 1260-510

Personal injury can result from air pressure.

Personal injury can result without following prop-


er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.

Maximum air pressure at the nozzle must be less


than 205 kPa (30 psi) for cleaning purposes.

g01290577
Illustration 123
Personal injury or death can result from engine
overspeed.
1. Open the engine access door on the right side of
the machine.
If the engine overspeeds, it can cause injury or
parts damage.

Be prepared to stop the engine by closing the air


off to the air inlets or by manually pushing down-
ward on the governor shutdown rod.

Personal injury or death can result from a fire.

Fuel leaked or spilled onto hot surfaces or electri-


cal components can cause a fire.

Illustration 124
g01290578 Clean up all leaked or spilled fuel. Do not smoke
while working on the fuel system.
2. Extend drain hose (2) into a suitable container.
Drain (1) is located under the primary fuel Turn the disconnect switch OFF or disconnect the
filter/water separator. battery when changing fuel filters.

3. Open drain (1). Allow the fluid to drain into the


NOTICE
container.
Do not fill fuel filter with fuel before installing the fuel
filter. Contaminated fuel causes accelerated wear to
4. After the separator is completely drained, close
fuel system parts.
drain (1) by hand pressure only. Dispose of the
drained fluid in a safe place.
88 SEBU8252-01
Maintenance Section
Fuel System Secondary Filter - Replace

3. Remove water collection bowl (1). Unscrew the


bowl from element (2).

4. Loosen element (2) from base (3). Remove the


element.

5. Install new element (2) onto mounting base (3).

6. Clean the water collection bowl. Install bowl (1)


on new element (2).

Note: The water collection bowl is reusable. When


you can no longer see the contents of the water
collection bowl, replace the water collection bowl.

7. Open the fuel shutoff valve at the rear of the


machine.

8. Prime the fuel system.

9. Prime the fuel system. See the Operation and


Illustration 125
g01289306 Maintenance Manual, “Fuel System - Prime”.

i02575726

Fuel System Secondary Filter -


Replace
SMCS Code: 1261-510-SE

The secondary fuel filter is located on the right front


side of the engine.

g01290579
Illustration 126

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


the machine.

2. Locate the fuel shutoff valve under the fuel tank at


the rear of the machine. Turn the handle of the
fuel shutoff valve counterclockwise in order to shut
off the fuel supply.

g01290608
Illustration 128

1. Remove the filter and properly discard the filter.

2. Clean the filter mounting base. Remove all of the


old seal. Coat the seal of the new filter with clean
diesel fuel.

3. Install the new filter by hand. When the seal


contacts the base, tighten 3/4 turn more.

4. Open the fuel supply valve.


g01290580 5. Prime the fuel system.
Illustration 127
SEBU8252-01 89
Maintenance Section
Fuel Tank Cap and Strainer - Clean

i02573812

Fuel Tank Cap and Strainer -


Clean
SMCS Code: 1273-070-STR; 1273-070-Z2;
1273-070

g01289342
Illustration 131

6. Remove the strainer.

7. Wash the strainer in clean, nonflammable solvent.

8. Install the strainer.


g01289351
Illustration 129
9. Install the fuel cap. Install the lock, if necessary.
Left side view

1. Remove the lock, if necessary. To remove fuel cap i02573763


(1), lift up on the lever. Turn the lever to the left
until the lever stops. Remove the cap. Fuel Tank Water and Sediment
- Drain
SMCS Code: 1273-543-M&S

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

Refer to Special Publication, NENG2500, “Caterpillar


Dealer Service Tool Catalog” for tools and supplies
Illustration 130
g01289343 suitable to collect and contain fluids on Caterpillar
products.
2. Rotate the fuel cap clockwise until three tabs (6)
drop in slots in the adapter. Rotate the lever (4) Dispose of all fluids according to local regulations and
clockwise until the lever stops. Lower lever (4) mandates.
over locking tab (5).
The drain valve is located under the fuel tank at the
3. Replace the filter in the fuel cap. rear of the machine.

4. To replace the filter, remove two screws that


secure filter (3) to the fuel cap. Remove filter (3),
valve (2), and the gaskets.

5. Install new components in the reverse order.


90 SEBU8252-01
Maintenance Section
Fuses and Circuit Breakers - Replace/Reset

i02574929

Fuses and Circuit Breakers -


Replace/Reset
SMCS Code: 1417-510; 1420-529; 1420

Fuses – Fuses protect the electrical


system from damage that is caused by
overloaded electrical circuits. Replace
a fuse if the element separates. If the fuse of
a particular electrical system requires frequent
replacement, check the electrical circuit. Repair the
electrical circuit, if necessary.

NOTICE
Always replace fuses with the same type and capacity
fuse that was removed. Otherwise, electrical damage
could result.

g01289306
Illustration 132 NOTICE
If it is necessary to replace fuses frequently, an elec-
1. Open the access cover on the rear of the machine. trical problem may exist.

Contact your Caterpillar dealer.

g01289318
Illustration 133

2. Open the drain valve and allow the moisture and


sediment to drain.

3. Close the drain valve.

4. Close the access cover.

g01289944
Illustration 134

Open the access door on the left side of the machine


to the circuit breakers and the fuses.
SEBU8252-01 91
Maintenance Section
Horn - Test

Wipers (10) – 20 Amp

Gauge (11) – 5 Amp

Fault Alarm (12) – 5 Amp

Blower (13) – 20 Amp

Circuit Breaker

g01289995
Illustration 135

Fuses are located behind the cover (not shown).

Fuses

g01290097
Illustration 137

Circuit Breaker/Reset – The 80 Amp main


circuit breaker is the only circuit breaker.
Push in the button in order to reset the
circuit breaker. If the electrical system is working
properly, the button will remain depressed.

Note: If the button does not remain depressed, check


the appropriate electrical circuit. Repair the electrical
circuit, if necessary.

i02054663

Horn - Test
g01290001 SMCS Code: 7402-081
Illustration 136
Fuse panel block Test the horn on a daily basis. Press downward on
the horn button in order to sound the horn. If the horn
Ignition Key (1) – 10 Amp does not sound, make the necessary repairs before
you operate the machine.
Flood Lights (Front) (2) – 15 Amp

Refrigerant Condenser (3) – 15 Amp

Operator Monitor (4) – 5 Amp

Forward Horn (5) – 10 Amp

Flood Lights (Rear) (6) – 10 Amp

Refrigerant Condenser (7) – 15 Amp

Gauge (8) – 10 Amp

Dome Light (9) – 15 Amp


92 SEBU8252-01
Maintenance Section
Hydraulic Control Linkage - Lubricate

i02575412

Hydraulic Control Linkage -


Lubricate
(If Equipped)
SMCS Code: 5063-086

g01290496
Illustration 139

1. To relieve the tank pressure, slowly remove


hydraulic oil filler cap (1).

g01290342
Illustration 138

The hydraulic control linkage is located on the right


side of the machine.

Lubricate two fittings.

i02575638

Hydraulic System Oil - Change


g01290524
SMCS Code: 5050-044 Illustration 140

The hydraulic oil filter is located behind the right side 2. Open the oil drain valve under the hydraulic oil
access door. tank and drain in a suitable container.

The hydraulic oil tank is located on the right side of 3. Close the valve.
the rear of the machine.

g01290365
Illustration 141
SEBU8252-01 93
Maintenance Section
Hydraulic System Oil Filter - Replace

g01290502
Illustration 142

4. Open the right side access door. Change hydraulic


oil filter (3). Refer to Operation and Maintenance
Manual, “Hydraulic System Oil Filter - Replace”.

5. See Operation and Maintenance Manual, g01290496


Illustration 143
“Capacities (Refill)” in order to determine the
amount of hydraulic oil that is needed to fill the
hydraulic oil tank. Fill the hydraulic oil tank.

6. Inspect the filler cap gasket. Replace the gasket if


the gasket is worn or damaged.

7. Install the oil filler cap.

8. Start the engine. Run the engine for a few minutes.

9. Stop the engine.

10. Maintain the oil level to the FULL mark (2) in


the sight gauge. See Illustration 142. Add oil, if
necessary. Illustration 144
g01290365

11. Close the right side access door. 1. To relieve the tank pressure, slowly remove
hydraulic oil filler cap (1).
i02575598

Hydraulic System Oil Filter -


Replace
SMCS Code: 5068-510

The hydraulic oil tank is located on the left side of


the rear of the machine.

The hydraulic oil filter is located behind the right side


access door.

g01290502
Illustration 145

2. Open the right side access door. Remove the


hydraulic oil filter element and filter housing(3).
94 SEBU8252-01
Maintenance Section
Hydraulic System Oil Level - Check

3. Remove the used filter element from the housing.


Properly discard the filter element.

4. Clean the inside of filter housing (3) with a clean


cloth.

5. Install the new hydraulic oil filter element.

6. Clean hydraulic oil filler cap (1) in a clean


nonflammable solvent. Install the cap.

7. Maintain oil level to the FULL mark (2) in the sight


gauge.

8. Close the right side access door. g01290365


Illustration 147
9. Start and run the engine at LOW IDLE for a few
minutes. 1. Maintain the oil level to the FULL mark (2) on the
sight gauge.
10. Stop the engine.
2. Remove hydraulic oil filler cap (1) and add the oil,
if necessary.
i02575427
3. Clean the hydraulic oil filler cap. Install the cap.
Hydraulic System Oil Level -
Check i02575523

SMCS Code: 5056-535-FLV; 7479 Hydraulic System Oil Sample


- Obtain
SMCS Code: 5095-008

Hot oil and hot components can cause personal


injury. Do not allow hot oil or hot components to
contact the skin.

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

Refer to Special Publication, NENG2500, “Caterpillar


g01290349 Dealer Service Tool Catalog” for tools and supplies
Illustration 146
suitable to collect and contain fluids on Caterpillar
products.
The hydraulic oil tank is located on the right side of
the rear of the machine. Dispose of all fluids according to local regulations and
mandates.
SEBU8252-01 95
Maintenance Section
Hydraulic System Oil Sample - Obtain

Obtain the Sample and the Analysis


In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
analysis at regular scheduled intervals in order to
monitor the condition of the hydraulic system and the
maintenance requirements of the hydraulic system.

Each oil sample should be taken when the oil is warm


and when the oil is well mixed in order to ensure that
the sample is representative of the oil in the hydraulic
system.

Obtain the S·O·S Sample

At operating temperature, the hydraulic tank is hot


and under pressure.

Hot oil and components can cause personal in- Illustration 148
g01290349
jury. Do not allow hot oil or components to contact
skin. 1. Remove hydraulic tank filler cap (1) slowly in order
to relieve any pressure.
Remove the filler cap only when the engine is
stopped, and the filler cap is cool enough to 2. Remove the filler strainer (not shown). Use a
touch with your bare hand. Remove the filler cap 1U-5718 Vacuum Pump or an equivalent pump.
slowly in order to relieve pressure. Insert the suction tube into the filler tube and draw
a sample of the hydraulic system oil.
NOTICE
Always use a designated pump for oil sampling, and 3. Replace the filler strainer and the hydraulic tank
use a separate designated pump for coolant sampling. filler cap.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This The recommended interval for oil samples is every
contaminate may cause a false analysis and an incor- 500 hours. The recommended hydraulic oil change
rect interpretation that could lead to concerns by both interval is 2000 hours.
dealers and customers.
Reference: Refer to “Lubricant Viscosities” in the
Maintenance Section of this publication for the
Obtain a sample of the hydraulic oil from the hydraulic correct fluid for your machine.
tank. The hydraulic tank is located on the right side of
the rear of the machine. Reference: Refer to the Operation and Maintenance
Manual, “S·O·S Oil Analysis”.

Reference: Refer to Special Publication, PEHP6001


for more information on obtaining a good oil
sample. Consult your Caterpillar dealer for complete
information and assistance in establishing an S·O·S
program for your machine.
96 SEBU8252-01
Maintenance Section
Oil Filter - Inspect

i02106227 i00057294

Oil Filter - Inspect Radiator Core - Clean


SMCS Code: 1318-507; 3067-507; 5068-507 SMCS Code: 1353-070; 1805; 1810

Inspect a Used Filter for Debris

g00100062
Illustration 150

g00100013 You can use compressed air, high pressure water,


Illustration 149
or steam to remove dust and other debris from the
The element is shown with debris. radiator core. However, the use of compressed air
is preferred.
Use a filter cutter to cut the filter element open.
Spread apart the pleats and inspect the element for See Special Publication, SEBD0518, “Know Your
metal and for other debris. An excessive amount of Cooling System” for the complete procedure for
debris in the filter element can indicate a possible cleaning the radiator core.
failure.

If metals are found in the filter element, a magnet can i02575152


be used to differentiate between ferrous metals and
nonferrous metals. Radiator Pressure Cap -
Clean/Replace
Ferrous metals can indicate wear on steel parts and
on cast iron parts. SMCS Code: 1353-070-Z2; 1353-510-Z2

Nonferrous metals can indicate wear on the


aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.
Pressurized system: Hot coolant can cause seri-
Small amounts of debris may be found in the filter ous burn. To open cap, stop engine, wait until ra-
element. This could be caused by friction and by diator is cool. Then loosen cap slowly to relieve
normal wear. Consult your Caterpillar dealer in order the pressure.
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.
SEBU8252-01 97
Maintenance Section
Ripper Linkage and Cylinder Bearings - Lubricate

i02575177

Ripper Tip and Shank Protector


- Inspect/Replace
SMCS Code: 6808-040; 6808-510; 6810; 6812-040;
6812-510

If equipped:

Tips

g01290126
Illustration 151

1. Open the access cover to the radiator cap on


top of the engine enclosure. Slowly remove the
radiator cap in order to relieve system pressure.
g01290171
Illustration 153
2. Inspect the radiator cap for damage, for deposits,
or for foreign material. Clean the radiator cap
When the ripper tip is worn close to the shank,
with a clean cloth. Replace the radiator cap if the
replace the ripper tip. If the tip is too blunt, the tip will
radiator cap is damaged.
not penetrate properly.
3. Install the radiator cap.
1. Raise the ripper. Place blocking under the ripper.
Lower the ripper onto the blocking. The ripper
i02578621 should be high enough so that the ripper tip can
be removed. Do not place the ripper too high.
Ripper Linkage and Cylinder
Bearings - Lubricate 2. If the ripper tip is worn, drive out pin (1). Remove
tip (2) and the shank pin retainer.
SMCS Code: 6313-086-BD, L4
3. Clean the shank pin retainer and the pin.

4. Install the new tip and the retainer.

5. Install pin (1) from the opposite side of the retainer.

6. Raise the ripper and remove the blocking.

7. Lower the ripper to the ground.

g01291928
Illustration 152
D7G ripper

1. Lubricate the twenty grease fittings for the ripper


arrangement.
98 SEBU8252-01
Maintenance Section
Seat Belt - Inspect

Shank

g00932801
Illustration 155
g01290209
Illustration 154 Typical example

When the ripper shank is worn or damaged, replace Check the seat belt mounting hardware (1) for wear
the ripper shank. or for damage. Replace any mounting hardware that
is worn or damaged. Make sure that the mounting
1. Raise the ripper. Place blocking under the ripper. bolts are tight.
Lower the ripper onto the blocking. The ripper
should be high enough so that the ripper shank Check buckle (2) for wear or for damage. If the buckle
can be removed. Do not place the ripper too high. is worn or damaged, replace the seat belt.

2. If the shank is worn or damaged, remove cotter Inspect the seat belt (3) for webbing that is worn or
pin (3). Then drive out pin (4). Remove shank (5). frayed. Replace the seat belt if the seat belt is worn
or frayed.
3. Install the new shank and pin (4).
Consult your Caterpillar dealer for the replacement of
4. Install cotter pin (3). the seat belt and the mounting hardware.

5. Raise the ripper and remove the blocking. Note: Within three years of the date of installation or
within five years of the date of manufacture, replace
6. Lower the ripper to the ground. 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
i02429589
buckle, and the seat belt retractor.
Seat Belt - Inspect
If your machine is equipped with a seat belt
SMCS Code: 7327-040; 7520 extension, also perform this inspection procedure for
the seat belt extension.
Always check the condition of the seat belt and the
condition of the seat belt mounting hardware before i02429594
you operate the machine. Replace any parts that are
damaged or worn before you operate the machine. Seat Belt - Replace
SMCS Code: 7327-510

Within three years of the date of installation or within


five years of the date of manufacture, replace the
seat belt . Replace the seat belt at the date which
occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.
SEBU8252-01 99
Maintenance Section
Sprocket Hub Bearings - Adjust

i02560021

Sprocket Hub Bearings -


Inspect
SMCS Code: 4054-040

g01152685
Illustration 156
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Date of manufacture (tag) (fully extended web)
(4) Date of manufacture (underside) (buckle)

Consult your Caterpillar dealer for the replacement of


the seat belt and the mounting hardware.
g01281496
Illustration 158
If your machine is equipped with a seat belt
extension, also perform this replacement procedure Inspect the sprocket hub bearing on new machines.
for the seat belt extension. Inspect the sprocket hub bearing on reconditioned
machines.
i02559987
See Operation and Maintenance Manual, “Sprocket
Sprocket Hub Bearings - Hub Bearings - Adjust”.
Adjust
i02560028
SMCS Code: 4054-025
Sprocket Hub Bearings -
Inspect
SMCS Code: 4054-040

g01281496
Illustration 157

Adjust the preload on the sprocket hub bearings.


Refer to the Service Manual or consult your
Caterpillar dealer. Illustration 159
g01281496

Check for oil leaks on both sides of the sprocket. If


the leakage is noticeable, the seals and/or bearings
need to be replaced. Refer to the Service Manualfor
this procedure. If the Service Manual is not available,
contact your Caterpillar dealer.
100 SEBU8252-01
Maintenance Section
Track - Check/Adjust

Check the bearing preload. The machine must be put


on stands. With the machine off the ground, this will NOTICE
reduce the load on the sprockets. Refer to the Service Do not attempt to tighten the track when dimension (X)
Manual For this procedure. If the Service Manual is is less than 3 mm (0.12 inch). Consult your Caterpillar
not available, contact your Caterpillar dealer. dealer for track service or instructions.

i02577880 2. Measure the “X” dimension.


Track - Check/Adjust 3. Stand on the track between the front idler and the
track carrier roller in order to produce as much
SMCS Code: 4170-036 track sag as possible.

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.

Check
Check the track adjustment. Check the track for wear
and for excessive dirt buildup.

1. Move the machine forward for a distance of two Illustration 161


g01291428
times the length of the machine. Stop the machine
Points (1, 2) are above the centerlines when the machine is
on a level surface without the use of the service stopped.
brake. Lower all the implements. Apply slight
down pressure to all the implements. Engage the 4. Attach one end of a string to the grouser tip on
parking brake lock lever. Place the transmission in the track shoe that is directly above track carrier
NEUTRAL and stop the engine. roller (1). Make the string tight by pulling on the
string. Attach the opposite end of the string to the
grouser tip on the track shoe (2) that is directly
above the front idler .

5. Measure the distance between the string and the


tip of the grouser that is on the track shoe directly
between the front idler and the track carrier roller
in order to obtain dimension (A).

6. Dimension (A) should be approximately 50 mm


(2.0 inch). If dimension (A) is not correct, adjust
the track.

g01281833
Illustration 160
Left track roller frame
SEBU8252-01 101
Maintenance Section
Track - Check/Adjust

Adjust

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.
g01281905
Loosen the relief valve only one turn. Illustration 163
(B) Mark on roller frame
1. Move the machine forward for a distance of two
times the length of the machine. Allow the machine 4. Mark the roller frame with a pencil or with a
to a stop without the use of the service brakes. marking pen. Make a mark (B) that is 12 mm
Shut off the engine. Adjust the tracks while you (0.50 inch) behind idler bearing support (5). This
are in the machine’s typical operating conditions. allows the necessary space for the front idler to
If packing conditions prevail on the job, the tracks retract.
should be adjusted with packing material.
5. Allow the idler to move back by opening relief
valve (3) ONE TURN ONLY. Move the machine in
REVERSE. This will help move the idler backward.

6. Close relief valve (3).

7. Add grease (MPGM) through adjusting valve (4)


until the mark on roller frame (B) is aligned with
the rear edge of idler bearing support (5).

8. Install the valve cover plate. Tighten the bolts to a


torque of 75 ± 15 N·m (55.5 ± 11.0 lb ft).

Note: The track sag after this adjustment procedure


should be 50 mm (2.0 inch). If track sag is not 50 mm
Illustration 162
g01281894 (2.0 inch), repeat the procedure.

2. Remove the cover for the track adjusting 9. Repeat the procedure on adjusting of the other
mechanism. track for the other side.

3. Add grease (MPGM) through adjusting valve (4) Bolt Torque for Track Shoes
in order to move the idler forward until the track
is fully tight.

g01162327
Illustration 164
102 SEBU8252-01
Maintenance Section
Track Pins - Inspect

The torque requirement for track shoe bolts is


300 ± 50 N·m (220 ± 40 lb ft). Tighten the bolts for NOTICE
an additional 120 degrees. If you are using bolts Striking the end of a track pin introduces a significant
with a master link, tighten the bolts to a torque of amount of end play into the track joint and can result
300 ± 50 N·m (220 ± 40 lb ft). Then, tighten the in early failures.
master bolts for an additional 180 degrees.
Consult your Caterpillar dealer’s Custom Track
i02560685 Service expert if you detect dry joints or leaks. Your
Caterpillar dealer’s Custom Track Service expert can
Track Pins - Inspect perform track inspection.
SMCS Code: 4175-040-PN
i02579170

Track Roller Frame Bearings -


Lubricate
SMCS Code: 4151-086

g01281974
Illustration 165

Fingers can be burned from hot pins and bush-


ings.
g01282062
Illustration 166
The pins and bushings in a dry joint can become Rear of track roller frames
very hot. It is possible to burn the fingers if there
is more than brief contact with these components. 1. Lubricate the two inner bearings. The bearings
are located on each roller frame.
Use the recommendations in order to extend the life
of the undercarriage. Use the recommendations in
order to avoid excessive downtime.

1. During the machine operation, listen for unusual


squeaking and for unusual squealing. This can
indicate a dry joint.

2. Check the machine for dry joints weekly.


Immediately after machine operation ,check for
any dry joints. After machine operation, lightly
touch the end of each track pin or bushing. Touch
the track pin or the track bushing with the back of
your hand. Make a mark on any dry track pin joint
that is very hot to the touch. Illustration 167
g01292050

3. Do not hit the ends of the track pins with a sledge 2. Lubricate the two outer bearings. The bearings
hammer in order to loosen the track joints. are located on each side of the machine.
SEBU8252-01 103
Maintenance Section
Transmission Magnetic Screen - Clean

i02577966 9. Start the engine. Run the engine at LOW IDLE


in NEUTRAL.
Transmission Magnetic Screen
- Clean
SMCS Code: 3030-070-MGS

1. Remove the floorplate.

g01291463 g01290342
Illustration 168 Illustration 170
Right view

g01291470
Illustration 171
g01282199
Illustration 169
(1) Cover
(2) Screen
(3) Magnet assembly

2. Remove cover (1).

3. Remove screen (2) and magnet assembly (3).

4. Wash the screen and the magnets in clean,


nonflammable solvent. Clean the magnets with a
cloth, stiff bristle brush or pressure air.

5. Install the magnets.


g01282066
6. Install the screen. Illustration 172
(A) Cold engine
7. Inspect the spring and the seal. If the seal is (B) Warm engine
damaged, install a new seal.
10. Open the door. Maintain the oil between the
8. Install the cover and the floorplate. ADD mark and the FULL mark on transmission
oil dipstick (4).
104 SEBU8252-01
Maintenance Section
Transmission Oil - Change

11. Remove transmission oil filler cap (5). If


necessary, add the oil.

12. Install the oil filler cap and close the door.

i02578230

Transmission Oil - Change


SMCS Code: 3030; 3080-044

Hot oil and components can cause personal in-


jury.

Do not allow hot oil or components to contact


skin.

Operate the engine in order to warm the oil. Park the g01291710
machine on level ground. Lower all attachments to Illustration 174
the ground. Apply slight downward pressure.
2. Remove the access cover in the bottom guard
Engage the parking brake switch. Stop the engine. assembly. Remove the oil drain plug from the
torque converter housing.
Drain Oil 3. Allow the oil to drain in a suitable container.

4. Clean the drain plugs. Install the drain plugs.

g01291687
Illustration 173
Rear view
g01291742
Illustration 175
1. Remove the transmission oil drain plug from the
bevel gear case. Drain the oil into a suitable 5. Remove cover (1) and screen (2) from the torque
container. converter housing.

6. Clean the cover and the screen in nonflammable


solvent.

7. Install the cover and the screen.

8. Change the filter element. See Operation and


Maintenance Manual, “Transmission Oil Filter -
Replace”.
SEBU8252-01 105
Maintenance Section
Transmission Oil - Change

9. Clean the transmission magnetic screen.


See Operation and Maintenance Manual,
“Transmission Magnetic Screen - Clean”.

Fill Oil

g01282066
Illustration 178

3. Add oil. Maintain the oil level to the “FULL” mark


on the dipstick.

Note: To determine the correct amount of oil, see


Operation and Maintenance Manual, “Capacities
(Refill)”.

g01290342
Illustration 176

1. Open the access door for the transmission oil


filler cap. The access door is on the right side of
the machine.

g01282504
Illustration 179
Front view

4. Unscrew the transmission breather and remove


the transmission breather.

5. Wash the transmission breather in a clean


nonflammable solvent.
g01291588
Illustration 177 6. Install the transmission breather.
2. Remove the transmission oil filler cap. 7. Start the engine. Run the engine at LOW IDLE.

8. On the dipstick, maintain the oil level between the


“ADD” mark and “FULL” mark.

9. Close the access door and stop the engine.


106 SEBU8252-01
Maintenance Section
Transmission Oil Filter - Replace

i02578003 2. Remove housing drain plug (2) and allow the oil
to drain in a suitable container.
Transmission Oil Filter -
Replace 3. Remove housing cover (1).

SMCS Code: 3067-510

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 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. Illustration 182
g01282322

Dispose of all fluids according to local regulations and 4. Remove the used filter element from the housing.
mandates.
5. Clean the inside of the housing with a clean cloth.
1. Open the left engine access door.
6. Clean the cover. Replace the damaged seal with
a new seal.

7. Install the new filter element.

8. Install the housing cover.

9. Clean the drain plug and install the drain plug.

i02578130

Transmission Oil Level - Check


SMCS Code: 3030-535-FLV; 3080-535-FLV
g01291476
Illustration 180
The transmission oil dipstick is located on the right
Right view side of the machine.

g01291542
Illustration 181
Section view of transmission oil filter
SEBU8252-01 107
Maintenance Section
Transmission Oil Sample - Obtain

2. Measure the oil level with the engine at LOW


IDLE. The oil should be at operating temperature.
Maintain the oil level to the FULL mark on
transmission oil dipstick (1).

3. Remove transmission oil filler cap (2).

4. Add oil, if necessary. Maintain the oil to the FULL


mark on transmission oil dipstick (1).

5. Clean transmission oil filler cap (2). Install the cap.

6. Close the access door.

i02578159

Transmission Oil Sample -


Obtain
SMCS Code: 3080-008
g01290342
Illustration 183

1. Open the right side access door.


Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.

Obtain the Sample and the Analysis


Obtain the sample of the transmission oil as close
as possible to the recommended sampling interval.
The recommended sampling interval is every 500
service hours. In order to receive the full effect of
S·O·S oil analysis, you must establish a consistent
trend of data. In order to establish a pertinent history
of data, perform consistent oil samplings that are
evenly spaced.
g01291564
Illustration 184
If the machine is operated under high load and/or
under high temperature conditions, sample all
fluids at the 250 hour interval.

Each oil sample should be taken when the oil is warm


and the oil is well mixed in order to ensure that the
sample is representative of the oil in the transmission.

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-
Illustration 185
g01282066 rect interpretation that could lead to concerns by both
(A) Cold engine
dealers and customers.
(B) Warm engine
108 SEBU8252-01
Maintenance Section
Window Washer Reservoir - Fill

i02578169

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.

g01290342
Illustration 186

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


machine.

g01291605
Illustration 188

Window Washer – The washer fluid bottle


is located on the rear of the machine above
the fuel tank. Remove the fluid bottle cap in
order to fill the washer fluid bottle.

g01291588
Illustration 187

2. Remove the transmission oil filler cap. Use a


1U-5718 Vacuum Pump or an equivalent pump.
Insert the suction tube in the filler tube and draw
an oil sample.

3. Replace the transmission oil filler cap on the filler


tube.

4. Close the access door on the right side of the


machine.

Reference: Refer to , “Lubricant Viscosities” in the


Maintenance Section of this manual for the correct
fluid for your machine.

Reference: Refer to Special Publication, PEHP6001


for more information on obtaining a good oil
sample. Consult your Caterpillar dealer for complete
information and assistance in establishing an S·O·S
program for your machine.
SEBU8252-01 109
Maintenance Section
Window Wipers - Inspect/Replace

i02578673

Window Wipers -
Inspect/Replace
(If Equipped)
SMCS Code: 7305-040; 7305-510

g01291973
Illustration 190

Clean all the cab windows and the door windows.

g01291965
Illustration 189

Inspect the front windshield wiper blade and the rear


windshield wiper blade. Replace any wiper blades
that are damaged or worn. Replace any wiper blades
that streak the windshield.

i02578689

Windows - Clean
SMCS Code: 7310-070; 7340-070

Use commercially available window cleaning


solutions to clean the windows.