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MAINTENANCE INTERVALS - Safety

1. Illustration 154 g01177484 Left side battery There are battery compartments on the left of the machine and on the right of the machine not shown Tighten the battery retainers on all batteries at every 1000 hour interval Perform the following procedures at every 1000 hour interval Check the following areas more often as required e Clean the top of the batteries with a clean cloth e Keep the terminals clean and coat the terminals with petroleum jelly e Keep the terminal covers in place 1 Open the battery access covers The battery access cover is located on the left side and right side of the machine outside the operator 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 3 Close the battery access covers SEBU8 135 10 131 Maintenance Section Battery Battery Cable or Battery Disconnect Switch Replace 102019456 Battery Battery Cable or Battery Disconnect Switch Replace SMCS Code 1401 510 1402 510 1411 510 1 Turn the engine start switch key to the OFF position Turn all of the switches to the OFF position 2 Turn the battery disconnect switch to the OFF position Remove the key 3 Disconnect the battery cable at the battery disconnect switch The battery disconnect switch is inside the left engine access door 4 Disc
2. g02161373 Illustration 243 Open the access door to the left side enclosure as shown Unscrew and remove the transmission breather 1 Perform steps 2 to 4 178 Maintenance Section Power Train Oil Change SEBU8135 10 103965809 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 li T at a Illustration 244 g01229675 High speed oil change transmission 1 Open the left engine compartment The machine is equipped for a high
3. Illustration 278 g00039582 Track Roller Frame Guides If dimension X is less than 45 3 mm 1 78 inch replace the track roller frame guides Reference Refer to Disassembly and Assembly Front Track Roller Frame Remove and refer to Disassembly and Assembly Front Track Roller Frame Install in the Service Manual for your machine Also consult your Caterpillar dealer for more information or for service 103409088 Walk Around Inspection SMCS Code 7000 040 Reference See Operation and Maintenance Manual Daily Inspection for more information SEBU8 135 10 191 Maintenance Section Window Washer Reservoir Fill 102044219 Window Washer Reservoir Fill SMCS Code 7306 544 NOTICE When operating in freezing temperatures use Caterpillar or any commercially available nonfreezing window washer solvent w Lnn Illustration 279 The washer fluid bottle is on the left side of the machine above the battery box Remove the fluid bottle cap in order to fill the washer fluid bottle 102849617 Window Wipers Inspect Replace SMCS Code 7305 040 7305 510 Illustration 280 g01420307 1 Rear window wiper 2 Front window wiper 3 Side window wiper Inspect the front window wiper blade the side window wiper blades and the rear window wiper blade Replace any wiper blades that are damaged or worn Replace any wiper
4. 145 Maintenance Section Engine Air Precleaner Clean 7 Inspect the primary filter element Inspect the filter element for holes and for tears by looking through the filter element Look toward a bright light Inspect the element for damaged gaskets or for dented metal parts Replace damaged filters Always crush damaged filter elements Properly discard the filter elements If you replace the primary filter element proceed to step 9 8 If the primary filter element is not damaged and the element has not been previously cleaned six times clean the element The filter element can be cleaned by using pressure air Use a maximum air pressure of 205 kPa 30 psi Direct the air from the clean side to the dirty side In order to show that the filter element has been cleaned mark the element The primary filter element can be cleaned up to six times NOTICE Do not clean the filter elements by bumping or tapping them Do not use filter elements with damaged pleats gaskets or seals Do not wash the filter elements 9 Push the filter element firmly in order to properly seat the element Write the date on the element if the primary element is replaced 10 Install the air cleaner cover 11 Close the access door if equipped Secondary Filter NOTICE Always replace the secondary filter element Never attempt to reuse it by cleaning The secondary filter element should be replaced at the time the primary element is s
5. 184 Maintenance Section Refrigerant Dryer Replace SEBU8135 10 104384157 Refrigerant Dryer Replace SMCS Code 7322 510 Personal injury can result from contact with refrig erant Contact with refrigerant can cause frost bite Keep face and hands away to help prevent injury Protective goggles must always be worn when re frigerant lines are opened even if the gauges in dicate the system is empty of refrigerant Always use precaution when a fitting is removed Slowly loosen the fitting If the system is still un der pressure release it slowly in a well ventilated area Personal injury or death can result from inhaling refrigerant through a lit cigarette Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Do not smoke when servicing air conditioners or wherever refrigerant gas may be present Use a certified recovery and recycling cart to prop erly remove the refrigerant from the air condition ing system Illustration 260 g02158878 The refrigerant dryer receiver is located on the front left side of the fuel tank The tube contains the desiccant that dries the liquid refrigerant Reference Refer to Service Manual SENR5664 Air Conditioning and Heating Manual for R 134a for the proper interval and the proper proce
6. 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 may appear to be damaged or if parts of the aftercooler system are repaired a leak test is highly recommended Refer to Special Instruction SEHS8622 Using the FT1984 Air to Air Aftercooler Leak Test Group The FT 1984 Aftercooler Testing Group can be used for aftercoolers that have hoses with an inside diameter of 102 mm 4 00 inches or 114 mm 4 50 inches For more detailed information on testing and inspection see Special Publication SEBD0518 Know Your Track Type Tractor Cooling System Replacing the Aftercooler Core Reference See Disassembly and Assembly RENR8223 Aftercooler Remove and Install for more information on removing the aftercooler core Clean Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes Radiator cores aftercooler cores and a c condenser cores needed to be cleaned regularly Adjust the frequency of cleaning according to the effects of the operating environmen
7. plies suitable to collect and contain fluids Dispose of all fluids according to local regulations and mandates Note The hydraulic tank is equipped with three filter elements The hydraulic tank is located on the right side of the machine 1 Park the machine on a level surface Lower the work tool to the ground Engage the parking brake 2 Turn the engine start switch key to ON 3 Move the hydraulic control levers through all of the positions in order to release pressure 4 Turn the engine start switch key to OFF Illustration 228 g02158954 5 Press button 1 on the breaker relief valve in order to relieve any tank pressure 6 Slowly remove filler cap 5 7 Remove the cover mounting bolts in three places 2 3 4 Rotate the covers counterclockwise in order to remove the covers Remove the cover seals Replace the cover seals if the seals are damaged g02161493 Illustration 229 8 Unscrew the nuts that are located at the bottom of the rods Remove the filter elements 8 9 and 10 by sliding the filters off rods 7 Properly discard the filter elements Install new filter elements Screw the nuts onto the rods and tighten the nuts to a torque of 10 1 5 N m 7 4 1 1 Ib ft If the rod was loosened during the removal of the retaining nut tighten the rod to a torque of 35 5 N m 25 3 Ib ft
8. 20 Amp 24 VA 12 VA Converter 20 Attachment 20 Amp Illustration 225 g01167541 A Front cover B Inside cover Cover 25 Fuse block Fuse cover 26 Plastic Power outlet 27 12 V Service Port 28 Connector HVAC blower 29 Reset button 15 Amp Fuse Puller 30 Auto Stop Fuse 31 175 Amp Fuses 32 Extra fuses Circuit Breaker Reset The circuit breaker for the HVAC blower 29 is behind the access cover under the left armrest of the operator seat See illustration 225 Circuit Breaker Reset 29 Push in the button in order to reset the circuit breaker If the electrical system is working properly the button will remain depressed If the button does not remain depressed check the appropriate electrical circuit Repair the electrical circuit if necessary 102861187 High Intensity Discharge Lamp HID Replace SMCS Code 1434 510 HID lamps operate at very high voltages To avoid electrical shock and personal injury disconnect power before servicing HID lamps HID bulbs become very hot during operation Before servicing remove power from lamp for at least five minutes to ensure lamp is cool NOTICE Although HID bulb materials may change over time HID bulbs produced at the time of the printing of this manual contain mercury When disposing of this com ponent or any waste that contains mercury please use caution and comply with any a
9. power train 1 4 Remove screen 3 5 Clean the screen in a clean nonflammable solvent 6 Inspect the O ring seal If the seal is damaged replace the seal 7 Install screen 3 elbow 2 and four bolts 6 8 Install four bolts 5 that hold tube assembly 4 to elbow 2 on the bottom of power train 1 9 Install the cover on the power train guard Suction Screen The suction screen for the power train is located below the cab Illustration 255 g02161101 1 Remove the bolts 7 and remove the cover 8 Remove the screen that is located behind the housing 2 Clean the screen in clean nonflammable solvent 3 Install the screen Install the cover 4 Refill the power train with oil Refer to Operation and Maintenance Manual Power Train System Oil Level Check and Operation and Maintenance Manual Capacities Refill 102612642 Radiator Core Clean SMCS Code 1353 070 1805 070 1810 070 Illustration 256 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 SEBU8 135 10 183 Maintenance Section Radiator Pressure Cap Clean Replac
10. radiator cap until the thermostat opens and the coolant level stabilizes Illustration 171 g01228797 Left side view 10 Add coolant in order to maintain the coolant level above the sight gauge in the coolant tank SEBU8 135 10 139 Maintenance Section Cooling System Coolant Extender ELC Add 11 If you need to add coolant daily check the cooling system for leaks 12 Inspect the radiator cap and the radiator cap seal for debris for foreign material or for damage Clean the radiator cap with a clean cloth Replace the radiator cap if the radiator cap is damaged 13 Install the radiator cap 14 Stop the engine 102462970 Cooling System Coolant Extender ELC Add SMCS Code 1352 538 When a Caterpillar Extended Life Coolant ELC is used an extender must be added to the cooling system The amount of extender is determined by the cooling system capacity Reference For additional information refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer Illustration 172 g01228778 The radiator cap is positioned in the top left side of the hood 1 Loosen the radiator cap slowly in order to relieve pressure Remove the radiator cap 2 It may be necessary to drain some coolant from the radiator so that Extender can be added to the cooling system NOTICE Care must be taken to ensure that fluids are
11. required Illustration 207 g01300294 Rear view of lubrication oil lines for the equalizer bar 102858067 Ether Starting Aid Cylinder Replace SMCS Code 1456 510 CD Breathing ether vapors or repeated contact of ether with skin can cause personal injury Person al injury may occur from failure to adhere to the following procedures Use ether only in well ventilated areas Do not smoke while changing ether cylinders Use ether with care to avoid fires Do not store replacement ether cylinders in living areas or in the operator s compartment Do not store ether cylinders in direct sunlight or at temperatures above 49 C 120 F Discard cylinders in a safe place Do not puncture or burn cylinders Keep ether cylinders out of the reach of unautho rized personnel To avoid possible injury be sure the brakes are ap plied and all controls are in Hold or Neutral when starting the engine 1 Open the rear engine access door on the right side of the machine The ether starting aid is located on the front side of the fender and the crossbeam 156 Maintenance Section Final Drive Oil Change SEBU8135 10 i jiii La g ith H AL ite a AEUR Illustration 208 g01230226 A Top view B Right side view A A Front view 2 Loosen the cylinder retaining clamp Unscrew the empty ether starting aid cylinder and remove the empty ether starting aid cylinder 3 Remove the use
12. 2 Add multipurpose grease MPGM through track adjustment valve 1 Add the MPGM until dimension A is correct 3 Operate the machine back and forth in order to equalize the pressure Allow the machine to coast to a complete stop Do not use the brakes 4 Remeasure dimension A Tight Track Adjustment 1 Loosen relief valve 2 by one turn of 360 degrees Allow the grease to escape 2 Close the relief valve Tighten the valve to a torque of 34 7 Nim 25 5 Ib ft 3 Add MPGM through track adjustment valve 1 Add grease until dimension A is correct 4 Install the access cover Bolt Torque for Track Shoes The torque requirement for track shoe bolts is 1500 150 N m 1100 100 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 1500 150 N m 1100 100 Ib ft Then tighten the bolts for an additional 180 degrees SEBU8 135 10 189 Maintenance Section Track Pins Inspect 102363445 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 Illustration 272 g01180440 1 Durin
13. P z je E g01049094 Illustration 274 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 shoe Place the block near the track idler Lower the machine onto the block 190 Maintenance Section Walk Around Inspection SEBU8135 10 g01049245 Illustration 275 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 LOR CA A ER a a g01049226 Illustration 276 3 Raise the front of the machine with the hydraulics of the dozer Place the block under the inside edge of the same track shoe Lower the machine onto the block g01049273 Illustration 277 4 Measure the distance between the two marks on the front roller frame If the distance between the two marks is greater than 4 5 mm 0 18 inch inspect the track roller frame guides for wear Repeat the entire procedure for the other side of the machine NOTICE Never build up the track roller frame guides with hard face welding This will cause serious wear damage to the guide slots in the front track roller frame
14. Sample Obtain asais 150 Engine Oil and Filter Change cee 151 Equalizer Bar End Pins Oil Level Check 154 Final Drive Oil Level Check ceeeeeee 157 Final Drive Oil Sample Obtain 0 157 Track Check AdjuSt 0 ecccceeeeeeteeeeeeeetteeeeeeeaes 187 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 QOD1AIN essin n ai iri a ai 140 Electronic Unit Injector Inspect Adjust 143 Engine Valve Lash Check Adjust 00 153 Engine Valve Rotators Inspect cee 154 Every 500 Service Hours Engine Crankcase Breather Clean 0 146 Final Drive Oil Change ereere 156 Fuel System Primary Filter Clean Replace 161 Fuel System Secondary Filter Replace 162 Fuel Tank Cap Filter and Strainer Replace Clean 2 0 0 2 cccceeeeeeeeeeeeceeeeeeeeeeeeeeteeeeees 164 Hoses and Clamps Inspect Replace 167 SEBU8 135 10 127 Maintenance Section Maintenance Interval Schedule Hydraulic System Oil Filters Replace 171 Hydraulic System Oil Sample Obtain 172 Power Train Breather Clean cccceeeees 177 Power Train Oil Filters Replace 08 179 Power Train System Oil Sample Obtain 180 Recoil Spring Compartment Oil Level Check 183 Eve
15. 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 144 Maintenance Section SEBU8135 10 Engine Air Filter Primary and or Secondary Element Clean Replace 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 103619440 Engine Air Filter Primary and or Secondary Element Clean Replace SMCS Code 1054 070 SE 1054 070 PY 1054 510 PY 1054 510 SE Primary Filter NOTICE Service the primary filter element only when the alert indicator for the intake air filter is flashing Do not open the filter compartment unless it is time for service Opening the filter compartment can cause dirt to get into the clean side of the filter housing NOTICE Extremely short air filter life can result if the preclean er system malfu
16. by pulling the belt backward Then slide the belt over coupling shaft 5 in a forward direction Install the belt on drive pulley 4 3 Insert a 12 7 mm 0 50 inch ratchet into the square hole in the tensioner Push up the ratchet and install the new belt on tensioner 6 4 Pry the belt tensioner in a clockwise direction in order to install the belt Note Remove the belt guards 1 2 as needed 5 To achieve the correct belt tension move the belt tensioner inward Tighten belt tensioner 6 in place Recheck the belt adjustment 6 Install top guard 9 to coupling guard 10 with eight bolts 8 as shown 7 Turn the battery disconnect switch to the ON position Note If a new belt is installed recheck the belt adjustment after 30 minutes of operation Note The second belt replacement will require loosening of the accessory drive shaft 8 Close the manhole cover in the cab 102859815 Braking System Test SMCS Code 4100 081 4267 081 Personal injury can result if the machine moves while testing If the machine begins to move during test reduce the engine speed immediately and engage the parking brake Note The brakes will not hold the machine if you select the 1F gear position Make sure that the area around the machine is clear of personnel and clear of obstacles Test the brakes on a dry level surface Fasten the seat belt before you test the brakes The following test is
17. can result from removing hoses or fittings that are under pressure Relieve the pres sure in the system before you remove hoses or fittings 2 3 4 Par g01961438 Illustration 151 1 Remove any buildup of grease at the fitting locations Check that each pin joint is receiving a fresh supply of grease 2 Check the grease level at the top vent port of the reservoir Reference Refer to Operation and Maintenance Manual Automatic Lubrication Grease Reservoir Fill lf Equipped for information on filling the reservoir 130 Maintenance Section Backup Alarm Test SEBU8135 10 102461882 Backup Alarm Test SMCS Code 7406 081 CATERPILLAR fa h F F h F Err ME lllustration 152 g01172855 The backup alarm is on the left rear of the machine Turn the engine start switch to the ON position in order to perform the test Apply the service brakes Disengage the parking brake switch Move the transmission control lever to the REVERSE position The backup alarm should sound immediately The backup alarm should continue to sound until the transmission control lever is moved to the NEUTRAL position or to the FORWARD position Illustration 153 g01172906 The sound level is nonadjustable 102857902 Battery Inspect SMCS Code 1401 040
18. 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 A FA ei o EA Ba A AVN o 7 aa f an ore Illustration 215 g01164665 1 Turn the red handle of the fuel shutoff valve in order to shut off the fuel supply The red handle is below the fuel tank 2 Open the access cover for the engine compartment The access cover is located on the right side of the machine L SLi j j A ie Illustration 216 g01229877 3 Loosen the retaining bolt for the filter housing case 4 Remove the filter with a strap wrench Remove the case and remove the element from the case 5 Clean the filter mounting base with clean nonflammable solvent Make sure that all of the old seal is removed o Coat the seal of the new filter element with clean diesel fuel N Install the new filter element by hand Instructions for the installation of the filters are printed on the side of each Caterpillar spin on filter For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter Open the fuel shutoff valve Prime
19. 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 until the cooling system has completely dried Allow the machine to sit overnight before operating the machine in the work mode 138 Maintenance Section Cooling System Coolant ELC Change SEBU8135 10 102462717 Cooling System Coolant ELC Change SMCS Code 1395 044 Reference For information about adding an extender to your cooling system refer to Operation and Maintenance Manual Cooling System Coolant Extender ELC Add 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 Flushing the ELC from the Cooling System If an ELC was previously used flush the cooling system with clean water No other cleaning agents are required Flushing a Standard Coolant from the Cooling System If you change to an ELC from another type of coolant use a Caterpillar cleaning agent to flush the cooling system After you drain the cooling system thoroughly flush the cooling system with clean water All of the cleaning agent must be removed from the cool
20. 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 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 Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Conditioner contains alkali Avoid contact with skin and eyes Illustration 177 g01425470 1 The housing 3 for the temperature regulators is located on the front of the engine 2 Remove the bolts 1 and 2 from the elbow Remove the elbow 3 Remove the two temperature regulators and the seals NOTICE Since Caterpillar engines incorporate a shunt design cooling system it is mandatory to always operate the engine with a thermostat Depending on load failure to operate with a thermo stat could result in either an overheating or an over cooling condition NOTICE If the thermostat is installed inco
21. hydraulic system requires additional hydraulic oil press button 2 on the breaker relief valve in order to relieve any tank pressure Slowly remove filler cap 1 and add oil through the filler tube 4 Clean filler cap 1 and install the filler cap i02858201 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 7542 008 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin SEBU8 135 10 173 Maintenance Section Indicators and Gauges Test NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Obtain the hydraulic oil sample as close as possible to the recommended sampling interval The recommended sampling interval is every 500 service hours In order to receive the full effect of S O S oil analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent oil samplings that are evenly spaced 1 Open the co
22. hydraulic tank capacity refer to Operation and Maintenance Manual Capacities Refill 16 Inspect the filler cap gasket Replace the gasket if damage or wear is evident 17 Install filler cap 1 18 Start the engine Run the engine for a few minutes 19 Maintain the oil level at the FULL mark 4 on the sight gauge Add oil if necessary 20 Stop the engine SEBU8 135 10 171 Maintenance Section Hydraulic System Oil Filters Replace 103954349 Hydraulic System Oil Filters Replace SMCS Code 5068 510 At operating temperature the hydraulic tank is hot and under pressure Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Before removing the filler cap press the valve re lief button on the hydraulic tank in order to relieve the tank pressure Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand Remove the filler cap slowly in order to relieve any remaining pressure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup
23. in order to check a viscous vibration damper for another C32 Acert engine see Service Manual RENR9Q798 Vibration Damper Check for typical instruction Note Refer 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 103662420 Engine Mounts and Equalizer Bar Inspect SMCS Code 1152 040 7206 040 Engine Mounts Caterpillar recommends checking the engine mounts for deterioration This will prevent excessive engine vibration that is caused from improper mounting Equalizer Bar End Pins Personal injury or death can occur from not fol lowing the proper procedure or the recommended tooling To prevent the possibility of injury or death follow the established procedure using the recommend ed tooling NOTICE The machine must be parked on a level surface to perform this procedure Personal injury or death can occur from not fol lowing the proper procedure or the recommended tooling To prevent the possibility of injury or death follow the established procedure using the recommend ed tooling NOTICE The machine must be parked on a level surface 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 t
24. machine applications is SAE 60 Fill the final drive with oil to the bottom of the filler plug opening See Operation and Maintenance Manual Capacities Refill 7 Inspect the condition of the seal of the filler plug Replace the plug seal if the plug seal is damaged SEBU8 135 10 157 Maintenance Section Final Drive Oil Level Check 8 Clean the filler plug and install the filler plug 9 Repeat Step 1 to Step 8 in order to change the oil in the other final drive 103795719 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 210 g02051933 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 The oil level should be at the bottom of the filler plug opening Add oil if necessary 4 Wipe the magnet in order to clean the plug 5 Install oil filler plug 2 6 Repeat Step 1 to Step 5 in order to check the oil level in the other final drive 103795729 Final Drive Oil Sample Obtain SMCS Code 3258 008 4050 008 7542 008 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair
25. of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Obtain the sample of the differential and final drive oil as close as possible to the recommended sampling interval The recommended sampling interval is every 250 service hours In order to receive the full effect of S O S oil analysis you must establish a consistent trend of data Illustration 211 g02052634 Oil sampling 158 Maintenance Section Frame Inspect SEBU8135 10 1 Position one final drive so that oil level mark 1 is horizontal 2 Remove oil filler plug 2 and obtain the oil sample with a proper suction device Use 1U 5718 Vacuum Pump to take the oil sample 3 Install oil filler plug 2 4 Repeat Step 1 to Step 3 in order to sample the oil in the other final drive 104713076 Frame Inspect SMCS Code 7051 040 Reference See Special Instruction REHS5390 Inspection Procedure for Certain D11R and D11T Track Type Tractor Main Frames for the information on this procedure 104666910 Fuel Lines Replace Low Pressure SMCS Code 1274 NOTICE Care must be taken to ens
26. 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 192 g01108806 The equalizer bar pads are under the front guard which is underneath the machine Inspect the equalizer bar pads for cracked rubber and for missing portions of rubber Consult your Caterpillar dealer for replacement parts and for replacement instructions 102859784 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 150 Maintenance Section Engine Oil Sample Obtain SEBU8135 10 Illustration 193 g01424605 1 Open the front engine access door that is on the left side of the machine Illustration 194 g01230331 5 SAFE OPERATING RANGE A B SAFE STARTING RANGE Illustration 195 g01230334 A Full mark at the engine running position SAFE OPERATING RANGE B Full mark with cold engine oil SAFE STARTING RANGE 2 Check the SAFE OPERATING RANGE side of dipstick 1 while the engine is running at low idle The oil should be at operating temperatu
27. the fuel cap Rotate the fuel cap clockwise until three tabs 1 drop into the slots in the adapter Rotate lever 2 clockwise until the lever stops Lower lever 2 over locking tab 3 102333657 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates The drain valve is under the fuel tank at the rear of the machine JE Ora gol g MV 5 RESO OO a et AWN ee g01164831 x Illustration 221 1 Open the drain valve with the yellow handle Use the drain tube and allow the water and the sediment to drain into a suitable container 2 Close the drain valve SEBU8 135 10 165 Maintenance Section Fuses and Circuit Breakers Replace Reset 104543336 Fuses and Circuit Breakers Replace Reset SMCS Code 1417 510 1420 Fuses These fuses protect the electrical system from damage that is caused by overloaded circuits Replace a fus
28. to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Obtain the sample of the transmission oil as close as possible to the recommended sampling interval The recommended sampling interval is every 500 service hours In order to receive the full effect of S O S oil analysis you must establish a consistent trend of data Illustration 252 g01307717 1 The oil sampling valve is located at the rear of the machine beneath the fuel tank Remove the protective cap Illustration 253 g01178670 Note Use the supplied probe and flush the fitting with oil into an approved container before obtaining oil sample 2 Use 169 8373 Fluid Sampling Bottle in order to obtain a sample 3 After you take a sample remove the cap with the tube and the probe from the bottle Discard the cap with the tube and the probe Install the sealing cap that is provided with 169 8373 Fluid Sampling Bottle 4 Replace the protective cap Refer to Operation and Maintenance Manual Lubricant Viscosities for the
29. used to determine whether the service brake is functional This test is not intended to determine the maximum brake holding effort The brake holding effort to hold the brake on this machine will be different This is because of variations in the engine setting in the power train efficiency and in the brake holding ability Compare the engine speed at the beginning of machine movement to the engine speed of a prior test This will be an indication of the amount of system deterioration SEBU8 135 10 133 Maintenance Section Bulldozer Blade Connectors Lubricate L Illustration 157 g01424614 1 Start the engine N Raise all attachments oo Depress the brake pedal A Release the parking brake switch a While the brake pedal is depressed move the directional control lever to the SECOND SPEED NEUTRAL position The control panel will indicate 2N 6 Select the FORWARD position The control panel will indicate 2F 7 Gradually increase the engine speed to full load speed The machine should not move 8 Move the throttle switch to LOW IDLE Turn on the parking brake switch 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 1039540
30. when the ladder moves The gap between the magnet and the switch must be close enough to function correctly 103996530 Ladder Hinge Oil Change SMCS Code 0634 510 OC 7254 510 OC Change the Oil 1 Park the machine 2 Clean the areas on the hinge block that are near the oil level fill plug and near the drain plug 3 Remove the drain plug from the hinge block Drain the oil completely into a suitable container Note Inspect the oil for particles Large particles indicate that a failure has occurred Consult your Cat dealer if this issue occurs 4 Install the drain plug Fill the hinge block with FDAO060 oil to the bottom of the oil level fill plug 5 Install the oil level fill plug Inspect the hinge block for leaks Repair any visible leaks 6 Start the engine See Starting Engine 102613792 Lift Cylinder Yoke Bearings Lubricate SMCS Code 5102 086 BD Illustration 236 g01308557 The fittings are on the left front side of the machine and on the right front side of the machine Lubricate the bearings by applying grease to the fittings 102106227 Oil Filter Inspect SMCS Code 1318 507 3067 507 5068 507 Inspect a Used Filter for Debris Illustration 237 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
31. 2 Check the oil level with dipstick 1 when the engine is running at low idle and the oil is at operating temperature HOT OIL Use the TRANSMISSION IN NEUTRAL ENGINE AT LOW IDLE AND OIL AT OPERATING TEMPERATURE side of the dipstick 1 Check when the transmission is in NEUTRAL and the engine is running at LOW IDLE The oil should be at operating temperature Maintain the oil level between the OPERATING ZONE marks This proceeding is the only accurate way to check the oil level COLD OIL Check the ENGINE STOPPED COLD OIL side of dipstick 1 while the engine is stopped Maintain the oil between the OPERATING ZONE marks This method should be used as reference only 3 Remove filler cap 2 If necessary add oil 4 Clean the filler cap and install the filler cap Replace the filter elements if the transmission oil filter indicator comes on during operation See Operation and Maintenance Manual Power Train Oil Filters Replace 5 Close the access door 103653872 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 SEBU8 135 10 181 Maintenance Section Power Train System Screens Clean 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
32. 41 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 138 Frame Inspect ccccceeceeeeeeseeeeeeeecaeceeeeeeeetees 158 128 Maintenance Section Automatic Lubrication Grease Tank Fill SEBU8135 10 103655206 Automatic Lubrication Grease Tank Fill If Equipped SMCS Code 7540 544 TNK 7540 544 Reservoir Location g01961437 Illustration 148 The grease reservoir 1 for the automatic lubrication system is located on the left side of the machine Procedure for Refilling Reservoir Location for Ground Level Fill A EZ EEN LD Dz nd g01962286 Illustration 149 The coupling on the filler assembly is located on the left hand ripper cylinder Filling the Reservoir 1 Ensure that the hose is filled with grease in order to prevent air from being pumped into the reservoir 2 Clean the coupling for filling and the coupling of the hose for filling 3 Attach the hose for filling to the coupling for refilling Refill the reservoir to the maximum level The air is allowed to bleed off during the filling of the reservoir 4 Disconnect the hose for filling and clean both couplings SEBU8 135 10 129 Maintenance Section Automatic Lubrication System Components Check Location for Lubricating 2 3 4 I
33. 60 Maintenance Section Fuel System Prime SEBU8135 10 Note Do not use HIS information to fabricate the low pressure fuel lines These hoses must be purchased from your Cat Dealer as complete assemblies 102858094 Fuel System Prime SMCS Code 1250 548 1258 548 If the engine does not start air may be trapped in the fuel lines to the engine Use the following procedure in order to purge air from the fuel lines Electric Fuel Priming Pump NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component 1 Park the machine on a level surface Engage the parking brake Turn the ignition switch to the OFF position US i i i j a Illustration 213 g01230304 2 Open the front engine access door on the right side of the machine Locate the switch for the fuel priming pump above the primary fuel filter 3 Move the switch for the electric fuel priming pump to the ON position Operate the fuel priming pump enough to fill the fuel lines and the fuel filters with fuel before turning OFF Note As the air is purged from the fuel system fuel pressure will increase Listen for the prim
34. 72 Bulldozer Blade Connectors Lubricate SMCS Code 6050 S N TPB1 Up N Illustration 158 g01308466 Carrydozer only Apply MPGM grease to the bulldozer blade connectors There are two grease fittings on each side 103954091 Bulldozer Tilt Brace and Tilt Cylinders Lubricate SMCS Code 5104 086 6050 086 6074 086 Lubricate the tilt cylinders and the tilt braces Illustration 159 g02158909 One grease fitting is located at the left front brace assembly or left tilt cylinder if equipped 134 Maintenance Section Cab Filter Fresh Air Clean Inspect Replace SEBU8135 10 One grease fitting is located at the rod end of the right tilt cylinder A grease fitting is located at the cylinder connection to each push arm 103423357 Cab Filter Fresh Air Clean Inspect Replace SMCS Code 7342 040 7342 070 7342 510 Note Clean the filters more often in dusty conditions Illustration 160 g01177020 1 Remove filter cover 1 The filter cover is located outside the left side of the cab 2 Loosen clamp 2 and remove filter element 3 3 The filter element can be cleaned by using pressure air Use a maximum air pressure of 205 kPa 30 psi Direct the air from the clean side to the dirty side 4 Look through the filter toward a bright light Inspect the element for damage Inspect the gaskets for damage Replace damaged filters 5 Install filter element 3 an
35. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved A SEBU8135 10 CATERPILLAR etary 2012 Operation and Maintenance Manual D11T Track Type Tractor GEB1 Up Standard TPB1 Up Carrydozer 126 Maintenance Section Maintenance Interval Schedule SEBU8135 10 104708893 Maintenance Interval Schedule SMCS Code 7000 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Note Before each consecutive interval is performed all maintenance from the previous interval must be performed Note If Cat HYDO Advanced 10 hydraulic oil is used the hydraulic oil change interval will change The normal interval of 2000 hours is extended to 3000 hours S O S services may extend th
36. Note Use Reverse Flow Elements only in the hydraulic tank for the D11T Track Type Tractor 9 Clean the covers and the screens in a clean nonflammable solvent 172 Maintenance Section Hydraulic System Oil Level Check SEBU8135 10 10 Inspect the cover seal and inspect the seal on the top of the tank in three places Replace the seals if the seals are damaged 11 Install the seals and the covers Tighten the cover mounting bolts to a torque of 45 7 Nem 32 5 lb ft Illustration 230 g01179210 12 Maintain the hydraulic oil to the FULL mark 6 on the sight gauge 13 Install filler cap 5 Hydraulic System Oil Level Check SMCS Code 5056 535 FLV 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 The hydraulic tank is on the right rear side of the machine 1 Lower the bulldozer and the ripper to the ground Stop the engine Illustration 231 g01179210 2 Maintain the oil level to the FULL mark on sight gauge 3 yOooONOoC OOO OR o S 3 i IW yp N Jg i ji Halt oj i of iL N oj il N ol Illustration 232 g01425530 Front view 3 If the
37. ain sufficient vision keep the Work Area Vision System WAVS camera lens and the display clean e ELES TGSGSOTG Illustration 163 g01223034 The WAVS display is located in the operator station 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 164 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 condensation snow or ice For more information on WAVS refer to Operation and Maintenance Manual SEBU8157 Work Area Vision System 103642430 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 Radiator core The AMOCS radiator cores cool the engine coolant A C condenser core The air conditioning condenser core cools the refrigerant in t
38. ali Avoid contact with the skin and eyes to prevent personal injury Open the front left engine access door The sight glass for the coolant level is located on the left side of the top water tank Illustration 174 g01228797 1 Maintain the coolant level above the sight glass Illustration 175 g01228778 The radiator cap is positioned in the top left side of the hood 2 If necessary open the radiator cap access cover Remove the radiator cap Add coolant into the coolant tank Do not overfill the tank 3 Inspect the radiator cap and the radiator cap seal for debris for foreign material or for damage Clean the radiator cap with a clean cloth Replace the radiator cap if the radiator cap is damaged 4 Install the radiator cap 102861797 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 SEBU8 135 10 141 Maintenance Section Cooling System Water Temperature Regulator Replace NOTICE Care must be taken to ensure that fluids are contained during performance o
39. auge 2 indicates that the ORS is FULL 4 Close the access door Reference For more information on the Oil Renewal System refer to Systems Operation RENR8160 Oil Renewal System Note Oil change intervals for machines that are equipped with an oil renewal system ORS are determined by monitoring scheduled oil sampling The oil change intervals are determined by close monitoring of the oil condition and engine wear metals Caterpillar prefers the scheduled oil sampling as the proper method of checking engine wear metals If scheduled oil sampling shows that the oil needs to be changed refer to the Operation and Maintenance Manual Engine Oil and Filter Change 102849053 Oil Renewal System Oil Level Check If Equipped SMCS Code 1348 535 Illustration 239 g01420223 1 Open the access door on the left side of the cab that is in front of the hydraulic tank 2 The oil level should be visible in the sight gauge 3 If the oil level is low engine oil should be added Reference See Oil Renewal System Oil Level Add for more information Note Keeping a daily maintenance log of all the additions of oil is necessary for determining whether the ORS is working properly 4 Close the access door 102454125 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 compon
40. blades that streak the window 102861784 Windows Clean SMCS Code 7310 070 7340 070 If equipped Use commercially available window cleaning solutions to clean the windows To clean the outside of the rear window from the inside of the cab remove the sliding section of the rear window Use the following procedure in order to remove the sliding section of the rear window Illustration 281 g01181500 1 Lift latch 1 in order to slide the small window Squeeze latch 2 in order to move the window from the CLOSED position 2 Move handle stop 3 to the UP position To move the handle stop to the UP position lift the handle and rotate the handle simultaneously Rotate the handle until the handle is vertical 3 Move the small section of the window to opening 4 in the upper window channel 4 Tilt the top of the window toward the inside of the cab Remove the window 5 Stay inside the cab in order to clean the outside of the rear window 6 After cleaning install the sliding section of the rear window 192 Maintenance Section Windows Clean SEBU8135 10 Cleaning From Ground Level Note Use the following method in order to clean a solid rear window Use commercially available window cleaning solutions in order to clean the windows Clean the outside of the windows from the groundor with the use of a man lift unless appropriate handholds are available Illustration 282 g00566124 Ty
41. bly 2 with lower ROPS mounting bolts B See Illustration 263 Illustration 263 g01666233 Inspect the ROPS structure the canopy and lower supports for any cracks or damage If the ROPS has any cracks in the welds in the castings or in any metal section consult your Caterpillar dealer for repairs Reference See Special Instruction SEBU6929 Inspection Maintenance and Repair of Rollover Protective Strructures ROPS and Attachment Installation Guidelines for further guidance information Inspect both sides of the Rollover Protective Structure ROPS for bolts that are loose broken or damaged If any broken ROPS bolts A or B are found replace all of ROPS bolts A or B Replace any missing ROPS bolts with original replacement parts only Tighten any loose bolts that are not broken or damaged Tighten the ROPS bolts to the following torque ROPS bolt A Tighten the sixteen upper bolts to 1800 200 N m 1325 150 Ib ft ROPS bolt B Tighten the twenty lower bolts to 2000 250 N m 1475 185 Ib ft Note Apply oil to all bolt threads for the ROPS before you install the ROPS bolts Failure to apply oil to the bolt threads can result in improper bolt torque Note Notify your Caterpillar dealer if broken bolts are found 104423622 Seat Belt Inspect SMCS Code 7327 040 Always inspect the condition of the seat belt and the condition of the seat belt mounting hardware bef
42. ccess to the torque converter Note Drain all fluids into a suitable container J ey RS ACY EA S Illustration 266 g01387611 SEBU8 135 10 187 Maintenance Section Track Check Adjust 2 Remove the bolts and drain valve body 1 from the torque converter as shown 3 Remove torque converter scavenge screen 2 from the torque converter housing 4 Wash the screen in a clean nonflammable solvent 5 Install torque converter scavenge 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 102859795 Track Check Adjust SMCS Code 4170 036 Illustration 267 g01308562 Check the track adjustment Check the track for wear and for excessive dirt buildup Personal injury or death can result from grease under 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 one turn only If track does not loosen close the relief valve and contact your Caterpillar dealer 1 Move the machine forward Allow the machine to coast to a stop without the use of the service bra
43. 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 5 4 L 1 42 US gal or 182 fl oz of Extender to the cooling system Illustration 173 g01228797 Left side view 4 Add coolant in order to maintain the coolant level above the sight gauge in the coolant tank 5 Inspect the radiator cap and the radiator cap seal for debris for foreign material or for damage Clean the radiator cap with a clean cloth Replace the radiator cap if the radiator cap is damaged 6 Install the radiator cap 140 Maintenance Section Cooling System Coolant Level Check SEBU8135 10 102463163 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 alk
44. correct fluid for your machine 104023412 Power Train System Screens Clean SMCS Code 3067 070 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any 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 Operate the machine in order to warm the power train oil The machine must be level Lower the work tools with slight down pressure When you change the power train oil clean the scavenge screens Drain the oil before you remove any screens An ecology drain is provided 182 Maintenance Section Radiator Core Clean SEBU8135 10 Power Train 1 Remove the cover on the power train guard in order to gain access to the screen Illustration 254 g01180914 Right side view 2 Remove four bolts 5 that hold tube assembly 4 to elbow 2 on the bottom of power train 1 3 Remove four bolts 6 that hold elbow 2 on
45. d gasket Install the new gasket that is provided with each new ether starting aid cylinder 4 Install the new ether starting aid cylinder Tighten the ether starting aid cylinder by hand Tighten the cylinder retaining clamp securely 5 Close the engine access door i03794750 Final Drive Oil Change SMCS Code 4050 044 FLV Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar 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 Illustration 209 g02051933 1 Position one final drive so that oil level mark 1 is horizontal Drain plug 3 will point downward 2 Remove drain plug 3 Take an SOS sample Allow the oil to drain into a suitable container 3 Inspect the drain plug seal Replace the drain plug seal if the drain plug seal is damaged 4 Clean the drain plug and install the drain plug 5 Remove oil filler plug 2 6 The recommended oil for most
46. d install clamp 2 6 Close filter cover 1 GEB386 Up and TPB174 Up Illustration 161 g01768834 1 Loosen three clamps 2 and remove filter cover 1 The filter cover is located outside the left side of the cab 2 Remove filter element 3 3 The filter element can be cleaned by using pressure air Use a maximum air pressure of 205 kPa 30 psi Direct the air from the clean side to the dirty side 4 Look through the filter toward a bright light Inspect the element for damage Inspect the gaskets for damage Replace damaged filters 5 Install filter element 3 and install filter cover 1 Close three clamps 2 102355725 Cab Filter Recirculation Clean Inspect Replace SMCS Code 7342 040 7342 070 7342 510 Note Clean the filters more often in dusty conditions Illustration 162 g01176720 SEBU8 135 10 135 Maintenance Section Camera Clean Adjust 1 Loosen the knob and remove the filter element that is located toward the left rear of the cab beside the seat 2 The filter element can be cleaned by using pressure air Use a maximum air pressure of 205 kPa 30 psi Direct the air from the clean side to the dirty side 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 filter element Camera Clean Adjust WAVS If Equipped SMCS Code 7348 In order to maint
47. dure 102613587 Ripper Linkage and Cylinder Bearings Lubricate SMCS Code 6313 086 BD L4 Illustration 261 g01308474 Lubricate twelve or more grease fittings as required 102613590 Ripper Tip and Shank Protector Inspect Replace SMCS Code 6808 040 6808 510 6812 040 6812 510 Illustration 262 g01308477 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 SEBU8 135 10 185 Maintenance Section Rollover Protective Structure ROPS Inspect 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 Raise the ripper and remove the blocking 7 Lower the ripper to the ground 103267881 Rollover Protective Structure ROPS Inspect SMCS Code 7325 040 Note The ROPS structure consists of the following components ROPS assembly 1 canopy with upper ROPS mounting bolts A and ROPS support assem
48. e 102464499 Radiator Pressure Cap Clean Replace SMCS Code 1353 070 Z2 1353 510 Z2 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 ee o gt q AN Illustration 257 g01229430 The radiator cap is positioned in the top left side of the hood 1 Slowly remove the radiator cap in order to relieve system pressure 2 Inspect the radiator cap for damage for deposits or for foreign material Clean the radiator cap with a clean cloth Replace the radiator cap if the radiator cap is damaged 3 Install the radiator cap i02859708 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 258 g01229489 1 Remove the cover plate for the oil filler that is beneath the final drive g01180061 Illustration 259 2 Maintain the oil level to the level mark on the inside of frame 3 Install the cover plate 4 Repeat the procedure for the other recoil compartment
49. e bottom of the transmission oil filter Drain the oil into a suitable container Reinstall the filter housing drain plug Illustration 248 g01180733 Right side view of left transmission oil filter 2 Remove the filter element cover assemblies 3 Remove the filter elements and properly discard the filter elements 4 Clean the filter element housing with a clean cloth 5 Inspect the seal If the seal is damaged replace the seal 6 Install the new filter elements Install the filter element housing cover 7 Start the engine I II Ht LU 7 fe li H T Hi D gii Illustration 249 g01307684 180 Maintenance Section Power Train System Oil Level Check SEBU8135 10 8 Maintain the oil level in the OPR ZONE on the dipstick 1 If necessary add oil through the filler tube 2 9 Stop the engine 103995569 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 The transmission oil dipstick is behind the engine access cover on the left side of the machine Illustration 250 g01307684 VOIL AT OPERATING TEMP YQ OPR ZONE 30L We ENGINE STOPPED COLD OILY Y eeOPR ZONE 30L Illustration 251 g00611366 1 Open the access door
50. e 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 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 223 g01299895 Illustration 222 g01167486 The fuse panel is beneath the access cover under the left armrest of the operator seat Illustration 224 g01402436 Open fuse Panel ROPS floodlights 1 15 Amp Ripper Floodlights 2 Cylinder 15 Amp ECM engine monitoring 3 Power train ECM 15 Amp Rear ROPS floodlights 4 15 Amp Auxiliary 5 15 Amp Spare 1 6 20 Amp GPS Radio Transmission Antenna 7 15 Amp Seat 8 Ripper or Implements 15 Amp Standard Converter 9 10 Amp Spare 2 10 15 Amp 166 Maintenance Section High Intensity Discharge Lamp HID Replace SEBU8135 10 Accugrade 11 15 Amp Wipers 12 15 Amp Ignition Key 13 10 Amp Fender Floodlights 14 15 Amp Horn 15 15 Amp Navigator 16 SV270 10 Amp Secondary Brake 17 10 Amp Unswitched Auxiliary 18 15 Amp Product Link 19 10 Amp Advisor Panel 20 15 Amp Implement ECM 21 15 Amp Power train ECM 22 15 Amp Engine ECM 23
51. e oil change even longer Consult your Cat dealer for details When Required Automatic Lubrication Grease Tank Fill 128 Automatic Lubrication System Components GHECKe ocat aad ns 129 Battery Battery Cable or Battery Disconnect Switch Replace icctasct2 cseestacg a a ac a aaa LA 131 Camera Clean Adjust cceeeeeeeeeentteeeeeeens 135 Cooler Cores and A C Condenser Clean 135 Cutting Edges and End Bits Inspect Replace 142 Engine Air Filter Primary and or Secondary Element Clean Replace cceceeeeeeceeecceeceeeeeeeteeetseens 144 Engine Air Precleaner Clean n c 145 Ether Starting Aid Cylinder Replace 155 Fuel System Prime cceccecceeeeeeeeeeeeteeeeeeeneaes 160 Fuses and Circuit Breakers Replace Reset 165 High Intensity Discharge Lamp HID Replace 166 Ladder AdjUSt scierie iseni irra rnana ean ER 174 Oil Filter Inspect ce eeeeceeeeceeeeeeeeeeeeseeeteeeeees 175 Oil Renewal System Oil Add eee 176 Radiator Core Clean cceceeeeeeecceceeeeeeeeeees 182 Radiator Pressure Cap Clean Replace 183 Ripper Tip and Shank Protector Inspect Replace moeras aeaee ad ieat fe tenet ial 184 Torque Converter Scavenge Screen Clean 186 Window Washer Reservoir Fill 0 006 191 Window Wipers Inspect Replace 05 191 Windows Clean ou cece ccc eeeeceseeeese
52. eeeeesaneeeeeaas 191 Every 10 Service Hours or Daily Backup Alarm Test eceeceeeeeeeteeeteeteees 130 Braking System Test 0 132 Cab Filter Fresh Air Clean Inspect Replace 134 Cooling System Coolant Level Check 140 Engine Oil Level Check cccceeeeeeeeeeeeeneeeees 149 Equalizer Bar End Pins Oil Level Check 154 Fuel System Primary Filter Water Separator DAU BEETA Ate check A E A tees eee ee cast 160 Fuel Tank Water and Sediment Drain 164 rome TeSt aaee aa fave ash ted a 167 Hydraulic System Oil Level Check nases 172 Indicators and Gauges Test 2 a 173 Oil Renewal System Oil Level Check 176 Pivot Shaft Oil Level Check 176 Power Train System Oil Level Check 180 Seat Belt Inspect oo eee ee eeeeeteeteeeeeeeeees 185 Walk Around Inspection sseeeeeeeeeeeeeeees 190 Every 50 Service Hours Bulldozer Blade Connectors Lubricate 133 Bulldozer Tilt Brace and Tilt Cylinders Lubricate eset raae adani etaa ize 133 Cab Filter Recirculation Clean Inspect Replace lenses arria ane eee 134 Lift Cylinder Yoke Bearings Lubricate 175 Ripper Linkage and Cylinder Bearings DUBICATCs coo eens a eted a a aa a A 184 Track Pins INSPe Ct imiinien eseis 189 Every 250 Service Hours Belt Inspect Replace cccceeeeeeeteeeteees 131 Engine Oil
53. eeve immediately after obtaining the sample in order to avoid contamination Never collect samples from expansion bottles Never collect samples from the drain for a system 1 Park the machine on a hard level surface Set the engine at low idle speed Illustration 176 g01425463 Right side view 2 The coolant sampling valve is located below the primary fuel filter on the front right side of the engine not shown Remove the protective cap from the sampling valve 3 Use a 169 8373 Fluid Sampling Bottle in order to obtain a sample 4 Replace the protective cap Submit the sample for Level 2 analysis 102859128 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 Replace the temperature regulators on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system The temperature regulators should be replaced after the cooling system has been cleaned Replace the temperature regulators while the cooling system is completely drained or while the cooling system coolant is drained to a level that is below the regulator housing NOTICE Failure to replace the engine s thermostat on a regu larly scheduled basis could cause severe engine dam age 142 Maintenance Section Cutting Edges and End Bits Inspect Replace SEBU8135 10 NOTICE Replace the thermostat on a regular basis in order to reduce the chance of unscheduled
54. ents to contact skin Open the left engine compartment SEBU8 135 10 177 Maintenance Section Power Train Breather Clean Illustration 240 g01224794 Front view Pivot shaft oil bottle 3 is between transmission filler tube 1 and left tractor fender 2 Maintain the oil within the limits of the dipstick for the oil reservoir Do not overfill the oil reservoir Hot oil can overflow the reservoir Remove the oil filler cap in order to add the oil to the oil reservoir i03966070 Power Train Breather Clean SMCS Code 3030 070 BRE Illustration 241 g01424562 1 The transmission breather is located in an area near the pivot shaft oil bottle The breather is on the bracket with the high speed oil change group for the power train Unscrew and remove the transmission breather Illustration 242 g01424582 2 Clean the breather in a clean nonflammable solvent Allow the breather to air dry 3 If the transmission breather is damaged or if the breather is not reusable discard the used breather element Install a new breather element 4 Install the transmission breather Alternate Location Some later machines will have an alternate location for the power train breather This location is inside the enclosure above the left fender
55. erviced for the third time The secondary filter element should also be replaced if the yellow piston in the filter element indicator en ters the red zone after installation of a clean primary element or if the exhaust smoke is still black NOTICE The filter should be kept in service for no longer than one year NOTICE Always leave the secondary filter element in place while you clean the air cleaner housing 1 Open the engine access door if equipped 2 Remove the air cleaner housing cover 3 Remove the primary filter element Refer to the section Primary Filter 4 Clean the inside of the air cleaner housing Illustration 182 g00470240 5 Remove the secondary filter element 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 if equipped 102467841 Engine Air Precleaner Clean SMCS Code 1055 070 Illustration 183 g01230827 1 Inspect the air inlet screens for dirt and for trash 2 Remove the screen Clean the screen if the screen is dirty 146 Maintenance Section Engine Crankcase Breather Clean SEBU8135 10 3 Inspect the precleaner tubes for dirt and for dust 4 Clean the precleaner tube with pr
56. essure air if the precleaner tube is dirty NOTICE Service the air cleaner only with the engine stopped Engine damage could result Run the engine at high idle If the engine air filter indicator still flashes service the air cleaners Stop the engine 102859690 Engine Crankcase Breather Clean SMCS Code 1317 070 Illustration 184 g01231478 Right side view Both of the crankcase breathers are located on the back of the engine 1 Remove tube 1 from the outlet of the breather and loosen clamp 2 2 Remove bolts 2 and remove the breather from the engine 3 Check the condition of the seal Replace the seal if the seal is damaged 4 Remove the breather element Wash the breather element and wash the breather in a clean nonflammable solvent 5 Shake the breather element until the breather element is dry You may also use pressurized air in order to dry the breather element 6 Check the condition of the tube Replace the tube if the tube is damaged 7 Install the element into the breather and install the breather with bolts 3 8 Install tube 1 onto the outlet of the breather cover and tighten clamp 2 9 Perform steps 1 through 8 for each crankcase breather 102467624 Engine Mounts and Crankshaft Vibration Damper Inspect SMCS Code 1152 040 1205 040 Damage to the vibration damper or failure of the vibration damper will increase torsional vibrations These vibrat
57. f 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 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 Caterpillar Machine Fluid Recommendations S O S Coolant Analysis for more information Perform a Coolant Analysis Level 2 at the initial 500 hours Perform the analysis yearly after the initial 500 hours Use the following guidelines for proper sampling of the coolant e Complete the information on the label for the sampling bottle before you begin to take the samples e Keep the unused sampling bottles stored in plastic bags Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample e Place the sample in the shipping sl
58. g the low pressure fuel lines 104384774 Hydraulic System Oil Change SMCS Code 5050 044 Interval Note If Cat HYDO Advanced 10 hydraulic oil is used the hydraulic oil change interval will change The normal interval of 2000 hours is extended to 3000 hours S O S Services may even extend the oil change to a longer interval Consult your Cat dealer for details Cat HYDO Oil Change Interval The standard Cat HYDO oil change interval is every 2000 service hours or 1 year A 4000 service hour or a 2 year maintenance interval for hydraulic oil change is available The extended interval requires S O S monitoring of the hydraulic oil The interval for S O S monitoring is every 500 hours The maintenance interval for the hydraulic oil filter is not changed Machines that are used in severe conditions are not included in the 4000 service hour or the 2 year maintenance interval Machines that are used in severe conditions must use the interval in the Maintenance Interval Schedule Cat HYDO Advanced 10 Oil Change Interval The standard Cat HYDO Advanced 10 oil change interval is every 3000 service hours or 18 months New machines are filled with Cat HYDO Advanced 10 oil at the factory A 6000 service hour or a 3 year maintenance interval for hydraulic oil change is available The extended interval requires S O S monitoring of the hydraulic oil The interval for S O S monitoring is every 500 hours The maintenance interva
59. g the machine operation listen for unusual squeaking and for unusual squealing This can indicate a dry joint 2 Check the machine for dry joints weekly Check for dry joints immediately after machine operation After machine operation lightly touch the end of each track pin or bushing Touch the track pin or the track bushing with the back of your hand Make a mark on any dry track pin joint that is very hot to the touch 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 102613794 Track Roller Frame Inspect SMCS Code 4151 040 DT iag iat Aa A Illustration 273 g01308563 Inspect the track roller frame for leaks Check the seal for the pivot shaft for oil leaks Check the track rollers and idlers for leaks Check the seal for the recoil spring for oil leaks i02363505 Track Roller Frame Guides Inspect SMCS Code 4177 040 Measure the rotational movement of the front roller frame relative to the rear roller frame A A O 5 A A
60. he air conditioning system 136 Maintenance Section Cooler Cores and A C Condenser Clean SEBU8135 10 Aftercooler Core go Same N TE E EA AeH Illustration 165 g01424403 Rear view of dual aftercooler Radiator Core Illustration 166 g01424408 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 A C Condenser Core Illustration 167 g01224464 The arrangement for the air conditioner condenser is located under the hood Remote A C Condenser Core In some machine arrangements the a c condenser core is remotely located A remote mounted a c condenser core is cooled by fans with electric drive Illustration 168 g01424471 An optional arrangement for the air conditioner condenser is located on the top of the machine Inspect Note Adjust the frequency of inspection according to the effects of the operating environment SEBU8135 10 137 Maintenance Section Cooler Cores and A C Condenser Clean Illustration 169 g01424503 Turn off the engine Open both of engine access doors
61. he 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 aiei N Ea Gila miko Illustration 235 g01424597 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 indicators of units Deg C kPa rpm and liters 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 Co
62. il 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 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 Illustration 198 g01178832 Top view 1 Open the crankcase drain access cover which is in the crankcase guard Illustration 199 g01178839 2 Remove the crankcase drain plug Open the drain valve Allow the oil to drain into a suitable container A drain hose may be attached to the drain valve to aid in draining 3 When the oil has completed draining from the crankcase close the drain valve Install the crankcase drain plug Close the crankcase drain access cover 4 Open the engine access cover on the left side of the machine SEBU8135 10 153 Maintenance Section Engine Valve Lash Check Adjust Illustration 200 g01230617 Left side view 5 Remove the engine oil filter elements from the front left side of the engine Discard the engine oil filter element properly Make sure that all of the old filter seal is removed from the filter base 6 Apply a thin coat of oil to the
63. ing pump to come under load Continue priming the fuel system until the pump is under load 4 Return the switch for the fuel priming pump to the OFF position 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 5 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 Note The electric fuel priming pump will only operate if the engine start switch key is in the OFF position Shut off the engine before any additional priming 6 Run the engine at the LOW IDLE position until the engine runs smoothly 7 Close the engine access door Reference If the engine does not start after several attempts consult your Caterpillar dealer 102858104 Fuel System Primary Filter Water Separator Drain SMCS Code 1263 543 Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any co
64. ing system Drain the Cooling System Illustration 170 g01228778 The radiator cap is positioned in the top left side of the hood 1 Slowly loosen the radiator cap in order to relieve system pressure Remove the radiator cap 2 The drain valve is under the radiator Remove the drain plug with the square drive hole 12 7 mm 0 5 inch Install a 25 4 mm 1 inch pipe with 1 11 1 2 NPTH thread into the drain valve The pipe requires 1 11 1 2 NPTF threads Clamp a 25 4 mm 1 inch hose to the pipe in order to direct the coolant into a suitable container 3 Loosen the small bolt on the side of the drain valve Open the drain valve plug in order to begin coolant flow Allow the coolant to drain into a suitable container 4 Close the drain valve Fill the system with a solution which consists of clean water and of cooling system cleaner The concentration of the cooling system cleaner should be 5 to 10 percent 5 Start the engine Run the engine for 90 minutes Stop the engine Drain the cleaning solution into a suitable container 6 While the engine is stopped flush the system with water Flush the system until the draining water is clear 7 Close the drain valve completely 8 Add the Extended Life Coolant Reference For the correct amount of ELC refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations 9 Start the engine Run the engine without the
65. ion Engine Oil and Filter Change SEBU8135 10 Table 19 D11T Series Engine Oil Change Interval Operating Conditions Severe Fuel Altitude Multigrade Sulfur above Oil Type sane Eee above 48330m 0 3 6000 ft CatDEO oso hr 500hr 250hr 250 hr Preferred ECF 2 250hr 500hr 250hr 250 hr Preferred 150 ECF 1 a 250 hr 250 hr hr 250 hr 1 The standard oil change interval for engines is 250 hours The extended oil change interval in this machine is 500 hours if the following conditions are met Acceptable operating conditions recommended oil types and an S O S oil sampling and analysis program are used This extended interval is not permitted for other machines Refer to the applicable Operation and Maintenance Manuals for the other machines 2 For sulfur content above 0 1 refer to this topic in the Manual SEBU6250 Caterpillar Machine Fluid Recommendations 3 Use Program B below to determine an appropriate interval Adjustment of the Oil Change Interval Note Your Cat dealer has additional information on these programs Program B Optimizing Oil Change Intervals Begin with a standard 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 analysis includes oil viscosity and infrared IR analysis of the o
66. ions 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 a Le Wis Illustration 185 g01305989 SEBU8 135 10 147 Maintenance Section Engine Mounts and Equalizer Bar Inspect The double viscous vibration damper limits torsional vibration effectively This C32 Acert engine uses a viscous vibration damper unlike the rubber vibration damper with alignment marks NOTICE Inspect the viscous vibration damper for signs of leak ing and for signs of damage to the case Either of these conditions can cause the weight to contact the case This contact can affect damper operation Also
67. kes 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 a Make sure that the ripper is raised if necessary 2 To measure the sag in the track stretch a string over the grousers that are between the sprocket and the front idler Take the measurement from the string to the top of the grouser at the maximum measurement Dimension A is the maximum distance between the string and the grouser Illustration 268 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 165 10 mm 6 5 4 inch 188 Maintenance Section Track Check Adjust SEBU8135 10 Illustration 269 g01118207 Track adjustment with carrier rollers If the machine is equipped with a carrier roller calculate the average of dimension B and dimension C The correct average value is 75 10 mm 3 0 0 4 inch Loose Track Adjustment is CAT AAO I VE gO I AX This g01019107 Illustration 270 NOTICE Do not attempt to tighten track when dimension 1 is 198 mm 7 8 inch or more Contact your Caterpillar dealer for track service or in structions 1 Remove the access cover Illustration 271 g01019116
68. l System Primary Filter Clean Replace SMCS Code 1260 070 PY 1260 510 PY A WARNING Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes A WARNING Personal injury or death can result from engine overspeed If the engine overspeeds it can cause injury or parts damage Be prepared to stop the engine by closing the air off to the air inlets or by manually pushing down ward on the governor shutdown rod A WARNING Personal injury or death can result from a fire Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters NOTICE Do not fill fuel filter with fuel before installing the fuel filter Contaminated fuel causes accelerated wear to fuel system parts 162 Maintenance Section Fuel System Secondary Filter Replace SEBU8135 10 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
69. l for the hydraulic oil filter is not changed Machines that are used in severe conditions are not included in the 6000 service hour or the 3 year maintenance interval Machines that are used in severe conditions must use the interval in the Maintenance Interval Schedule Reference Refer to Operation and Maintenance Manual Lubricant Viscosities for more information on hydraulic oils Change the Hydraulic Oil 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 170 Maintenance Section Hydraulic System Oil Change SEBU8135 10 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 1 Operate the machine in order to warm the oil Park the machine on a leve
70. l surface Lower the work tool to the ground Engage the parking brake 2 Turn the engine start switch key to ON 3 Move the hydraulic control levers through all of the positions in order to release pressure 4 Turn the engine start switch key to OFF Illustration 227 g01425514 5 The hydraulic tank is located on the right side of the machine Press the button on breaker relief valve 2 in order to relieve any tank pressure 6 Slowly remove filler cap 1 7 Clean the filler strainer and the filler cap in a clean nonflammable solvent 8 Remove oil drain plug 3 The oil drain plug is located on the front of the hydraulic tank 9 Attach a hose to a swivel Install the swivel and the hose into the drain plug opening A pipe nipple 10 cm 4 inch and a hose can also be used Use a 25 4 mm 1 inch pipe with 1 11 1 2 NPTF threads Do not tighten the pipe 10 Rotate the swivel clockwise in order to open the internal drain valve Allow the oil to drain into a suitable container 11 Remove the swivel The valve for the hydraulic tank will close 12 Clean drain plug 3 and install the drain plug Tighten the drain plug to a torque of 90 15 N m 65 10 Ib ft 13 Change the hydraulic oil filter Reference For the correct procedure refer to Operation and Maintenance Manual Hydraulic System Oil Filter Replace 14 Install the filler strainer 15 Fill the hydraulic oil tank Reference For the
71. ling NOTICE The machine must be parked on a level surface to perform this procedure Personal injury or death can occur from not fol lowing the proper procedure or the recommended tooling To prevent the possibility of injury or death follow the established procedure using the recommend ed tooling NOTICE The machine must be parked on a level surface to perform this procedure Note All the weight of the machine must be removed from the equalizer bar Equalizer bar must have free movement in order to be measured To check the equalizer bar center pin for looseness and for unusual wear perform the following steps SEBU8135 10 149 Maintenance Section Engine Oil Level Check j oO Illustration 189 g01108801 1 Clean the areas that are around the center pin and equalizer bar im t A GO LY lo q o 0 Illustration 190 g01108803 2 Put a suitable floor jack in position under the main frame as shown Illustration 191 g01108804 3 Position a dial indicator on the equalizer bar and place the probe of the dial indicator under the center of the frame for the pin Set the dial indicator to zero 4 Jack up the 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
72. llation instructions that are provided by the supplier of the filter Open the fuel shutoff valve Prime the fuel system Reference See Operation and Maintenance Manual Fuel System Prime for more information 164 Maintenance Section Fuel Tank Cap Filter and Strainer Replace Clean SEBU8135 10 102859700 Fuel Tank Cap Filter and Strainer Replace Clean SMCS Code 1273 070 Z22 1273 070 STR CATERPILLAR mE _ FH a en O R h F F a F eee ee Wa g01181726 Illustration 219 The fuel cap is on the rear of the machine The cap is on the left side of the machine Only vented fuel caps have filters Illustration 220 g00103986 1 Lift lever 2 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 In order to remove the fuel strainer lift the fuel strainer upward 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 5 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
73. llustration 150 90198143 2 3 Lift cylinder yoke left and right pivot bearings two locations on each side Ripper tilt cylinder left and right frame pivot bearings Ripper lift cylinder left and right frame pivot bearings Ripper frame left and right pivot bearings Ripper lift cylinder left and right pivot bearings Beam Carriage left and right pivot bearings Ripper tilt cylinder left and right pivot bearings 4 5 6 7 8 9 wero ye rere a Recommended Lubricant Table 18 lists the recommended lubricant that is used for the automatic lubrication system Table 18 Recommended Lubrication for the Automated Lubrication System 1 Grease NLGI C F Caterpillar 1 18 29 0 85 Autolube Caterpillar 2 1 41 30 105 Autolube Caterpillar 0 29 10 20 50 Autolube Caterpillar 000 59 4 75 40 Arctic Platinum Caterpillar 2 4 66 40 150 Desert Gold 1 In order to use a non Caterpillar lubricant the supplier must certify that the lubricant is compatible with Caterpillar s grease Otherwise each pin joint should be fully flushed with the new lubricant in order to entirely remove the Caterpillar lubricant Failure to meet this requirement may lead to failure of a pin joint due to premature breakdown of the lubricant 103654919 Automatic Lubrication System Components Check SMCS Code 7540 535 A pressure hazard is present Severe personal in jury or death
74. mpartment covers that are above on the right side fender Illustration 233 g01424170 2 Remove the protective cap from the oil sampling port Illustration 234 g01178670 Note Use the supplied probe and flush the fitting with oil into an approved container before obtaining oil sample 3 Use 169 8373 Fluid Sampling Bottle in order to obtain the sample 4 After you take a sample remove the cap with the tube and the probe from the bottle Discard the cap with the tube and the probe Install the sealing cap that is provided with 169 8373 Fluid Sampling Bottle 5 Replace the protective cap 6 Close the compartment covers Refer to Operation and Maintenance Manual Lubricant Viscosities for the correct fluid for your machine 102896247 Indicators and Gauges Test SMCS Code 7450 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 174 Maintenance Section Ladder Adjust SEBU8135 10 The self test verifies that t
75. mpo 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 SEBU8 135 10 161 Maintenance Section Fuel System Primary Filter Clean Replace NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component The fuel system water separator is located on the front right side of the engine Illustration 214 g01424117 Front view 1 Primary filter element 2 Water separator bowl 3 Drain valve 4 Drain hose Water separator bowl 2 should be monitored daily for signs of water If water is present drain the water from the bowl 1 Open the right engine access door 2 Place drain hose 4 on the outside of the machine 3 Open drain valve 3 The drain is a self ventilated drain Catch the draining water in a suitable container Dispose of the water properly 4 Close drain valve 3 5 Reposition drain hose 4 6 Close the engine access door 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 i02859697 Fue
76. nctions If air filter life is drastically re duced from typical for the operating conditions con sult your Caterpillar Dealer The exhaust system dust ejector for the strata tube precleaner must pull a min imum vacuum of 508 mm 20 inch of water NOTICE Service the engine air filters with the engine stopped Engine damage could result NOTICE Always leave the secondary filter element in place while you clean the primary element or while you clean the air cleaner housing NOTICE Do not use the filter for longer than one year 1 Open the engine compartment s access door if equipped Illustration 180 g00470852 2 Remove the air cleaner cover 1 Pull out in order to remove the element 3 Remove the primary filter element 2 from the air cleaner housing 4 Mark the secondary filter element in order to show that the primary filter element has been serviced The secondary filter element should be replaced when the primary filter element is serviced for the third time Refer to the section Secondary Filter Illustration 181 g00470857 5 Clean the inside of the air cleaner housing Keep the secondary filter element in place while you clean the housing 6 If the primary filter element has not been cleaned six times inspect the primary filter element If the primary filter element has been cleaned six times replace the primary filter element Proceed to Step 9 SEBU8 135 10
77. nformation refer to Specifications SENR3130 Torque Specifications 8 Strike the bolt heads with a hammer Tighten the bolts to the specified torque again 9 Raise the bulldozer blade and remove the blocking Lower the bulldozer blade to the ground 102861840 Electro Hydraulic Oil Filter Change SMCS Code 5068 510 FI At operating temperature the hydraulic tank is hot and under pressure Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand Remove the filler cap slowly in order to relieve pressure Illustration 179 g01425501 1 The hydraulic tank is located on the right side of the machine Press the button on breaker relief valve 2 next to the filler cap 1 in order to relieve any tank pressure Open the filler cap by turning the cap counterclockwise 2 Remove filter housing 3 o Remove the filter element Properly discard the filter element 4 Install a new filter element 5 Install filter housing 3 Lubricate the seal with hydraulic oil 6 Maintain the hydraulic oil to the FULL mark 4 in the sight gauge N Install hydraulic tank filler cap 1 i02061807 Electronic Unit Injector Inspect Adjust SMCS Code 1290 025 1290 040 The Electronic Control module produces high voltage
78. ng conditions e Hoses which exhibit signs of leakage which are not the result of loose couplings or clamps e Hoses which are cracked Inspect all hose couplings for leaks Replace any e Hoses which are soft hose that exhibits signs of coupling leakage e Outer covering that is chafed or cut SEBU8 135 10 169 Maintenance Section Hydraulic System Oil Change Inspect all clamps for the following conditions Replace any parts that exhibit signs of any of the following conditions e Missing or damaged grommets e Missing fasteners e Missing clamps Failure to replace a non metallic fuel line hose which exhibits any of the above conditions may result in a leak Replace the Hoses and the Clamps 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 or refer to Special Pub lication PECJ0003 Caterpillar Shop Supplies and Tools Catalog for tools and supplies suitable to col lect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Reference Refer to the Engine Disassembly and Assembly for information on removing and installin
79. nsult 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 104371323 Ladder Adjust SMCS Code 0634 025 7254 025 Adjust the Access Ladder Do not ride on ladder or stand on platform while machine is moving NOTICE To avoid damage to the ladder during machine oper ation keep the ladder in the LATCHED position 1 Position adjustment for the hinge a Adjust the hinge so that the ladder is parallel to the top surface of the fender with the ladder in the UP position 2 Adjustment for the location of the latch a The latch should be adjusted so that the pins for the latch are equally engaged in the top and the bottom of the ladder 3 Adjustment for the contact plates on the latch a The contact plates on the latch should be adjusted in order to prevent any vertical movement or any side to side movement of the ladder when the latch pins are engaged in the ladder 4 Adjustment for the location of the proximity switch a With the ladder in the Up position adjust the proximity switch so that the switch and the magnet are aligned SEBU8 135 10 175 Maintenance Section Ladder Hinge Oil Change b There must be a gap between the magnet and the switch in order to prevent contact
80. o be measured To check the equalizer bar end pin for movement and unusual wear perform the following steps Illustration 186 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 148 Maintenance Section Engine Mounts and Equalizer Bar Inspect SEBU8135 10 Illustration 187 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 188 g01108798 5 Put a suitable floor jack in position under the end of the equalizer bar 6 Jack up the equalizer bar and take a reading on the dial indicator in order to determine the amount of wear Note Schedule the end pin joint for repair if the reading on the dial indicator exceeds 1 50 mm 059 inch 7 Repeat the inspection and the measurement procedure for the other end of the equalizer bar and end pin Consult your Caterpillar dealer for an inspection and for repair instructions Equalizer Bar Center Pin Personal injury or death can occur 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 too
81. onnect the negative battery cable at the battery 5 Replace the disconnect switch the battery cables or the batteries as required 6 Connect the negative battery cable at the battery 7 Connect the negative battery cable at the battery disconnect switch 8 Install the key and turn the battery disconnect switch to the ON position Battery Recycle Always recycle a battery Never discard a battery Always return used batteries to one of the following locations e A battery supplier e An authorized battery collection facility e Recycling facility 102859785 Belt Inspect Replace SMCS Code 1397 040 1397 510 Your engine is equipped with a serpentine belt that drives the alternator and the air conditioner compressor if equipped This engine is equipped with a belt tightener that automatically adjusts the belt to the correct tension Inspect the Belt 1 Park the machine on level ground Lower the dozer blade to the ground Move the transmission control to the NEUTRAL position and engage the parking brake Shut off the engine 2 Turn the battery disconnect switch to the OFF position 3 Open the rear engine access door that is located on the left hand side of the machine The serpentine belt is located just forward of the cab firewall Illustration 155 g01228154 Rear view 4 Inspect the condition of serpentine belt 3 Replace the serpentine belt if excessive wear or cracking has occurred Wear d
82. ore you operate the machine Replace any parts that are damaged or worn before you operate the machine Illustration 264 g02620101 Typical example 186 Maintenance Section Seat Belt Replace SEBU8135 10 Inspect buckle 1 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect seat belt 2 for webbing that is worn or frayed Replace the seat belt if the webbing is worn or frayed Inspect all seat belt mounting hardware for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension Contact your Cat dealer for the replacement of the seat belt and the mounting hardware Note The seat belt should be replaced within 3 years of the date of installation A date of installation label is attached to the seat belt retractor and buckle If the date of installation label is missing replace belt within 3 years from the year of manufacture as indicated on belt webbing label buckle housing or installation tags non retractable belts 104421974 Seat Belt Replace SMCS Code 7327 510 The seat belt should be replaced within 3 years of the date of installation A date of installation label is attached to the seat belt retractor and buckle If the date of installation label is missing replace belt wi
83. ou must establish a consistent trend of data In order to establish a pertinent history of data perform consistent oil samplings that are evenly spaced 1 Open the front engine access door that is on the left side of the machine SEBU8135 10 151 Maintenance Section Engine Oil and Filter Change Illustration 196 g01230640 2 Remove the protective cap Illustration 197 g01178670 169 8373 Fluid Sampling Bottle Note Use the supplied probe and flush the fitting with oil into an approved container before obtaining oil sample 3 Obtain a sample with 169 8373 Fluid Sampling Bottle 4 After you take a sample remove the cap with the tube and the probe from the bottle Discard the cap with the tube and the probe Install the sealing cap that is provided with 169 8373 Fluid Sampling Bottle 5 Replace the protective cap 6 Close the engine access door Refer to Operation and Maintenance Manual Lubricant Viscosities for the correct fluid for your machine 104384279 Engine Oil and Filter Change SMCS Code 1308 510 1318 510 Selection of the Oil Change Interval 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 Publica
84. partment 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 Observe the pressure indicator on the dash for the fuel filters If the filters are plugged replace the secondary fuel filter elements A F A opat Bii pam ES Di on S FH ie ot Fa ie 3 att haart J g01230294 Illustration 217 Before you replace the secondary fuel filter elements clean the primary fuel filter element The secondary fuel filters are behind the front engine access door on the right side of the machine Illustration 218 1 g01164665 Shut off the fuel supply The fuel shutoff valve with the red handle is under the fuel tank on the rear of the machine Remove the filter elements Discard the filter elements properly Clean the filter housing base Make sure that all of the old seal is removed Coat the seal of the new filter elements with clean diesel fuel Install the new filter elements by hand Instructions for the installation of the filters are printed on the side of each Caterpillar spin on filter For non Caterpillar filters refer to the insta
85. pical example Use a pole with a squeegee in order to reach the high areas of the window
86. pplicable laws e Remove the electrical power from the high intensity discharge lamp HID The electrical power must be removed from the HID lamp for at least five minutes in order to ensure that the bulb is cool N Disassemble the housing for the HID lamp in order to have access to the bulb Note On some HID lamps the bulb is an integral part of the lens assembly The bulb is not removed separately from the lens assembly Replace the entire lens assembly on these HID lamps 3 Remove the bulb from the HID lamp 4 Install the replacement bulb in the HID lamp SEBU8 135 10 167 Maintenance Section Horn Test If the bulb is an integral part of the lens assembly install the replacement lens assembly in the HID lamp Note In order to avoid failure to the bulb that is premature avoid touching the bulb s surface with your bare hands Clean any fingerprints from the bulb with alcohol prior to operation 5 Reassemble the housing for the HID lamp Ensure that any printing on the lens is oriented correctly with respect to the HID lamp s mounting position on the machine 6 Reattach the electrical power to the HID lamp 7 Check the HID lamp for proper operation Note Consult your Caterpillar dealer for additional information on HID lamps 102054663 Horn Test SMCS Code 7402 081 Test the horn on a daily basis Press downward on the horn button in order to sound the horn If the horn does no
87. re Maintain the oil level to the FULL mark Check the SAFE STARTING RANGE side of dipstick 1 before starting the engine when the engine oil is cold Maintain the oil level to the FULL mark Note When you operate the machine on severe slopes the oil level in the engine crankcase must be in the SAFE OPERATING RANGE zone of the dipstick 3 Remove oil filler cap 1 If necessary add oil 4 Clean the oil filler cap and install the oil filler cap 5 Close the engine access door Engine Oil Sample Obtain SMCS Code 1000 008 7542 008 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Obtain the sample of the engine oil as close as possible to the recommended sampling interval The recommended sampling interval is every 250 service hours In order to receive the full effect of S O S oil analysis y
88. rrectly it will cause the engine to overheat 4 Install new seals and install new temperature regulators Install a new housing gasket 5 Install the elbow 102349716 Cutting Edges and End Bits Inspect Replace SMCS Code 6801 040 6801 510 6804 040 6804 510 Illustration 178 g01051836 1 Raise the bulldozer blade and block up the bulldozer blade at a minimum height 2 Remove the bolts Then remove the cutting edge and the end bits 3 Thoroughly clean all contact surfaces 4 Inspect the opposite side of the cutting edge If the opposite side of the cutting edge is not worn turn the opposite side of the cutting edge outward and install the cutting edge 5 If both sides of the cutting edge are worn install a new cutting edge SEBU8 135 10 143 Maintenance Section Electro Hydraulic Oil Filter Change Note When the cutting edge is within 10 mm 0 4 inch of the bottom of the support replace 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 inch of the bottom of the support replace the end bit When the end bit is within 10 mm 0 4 inch of the outside edge of the support replace the end bit Do not allow any wear to occur on the support 7 Install all bolts and tighten the bolts to the specified torque Reference For more i
89. ry 1000 Service Hours or 6 Months Battery Inspect ee ceeeeeeeeeeeeeeeeeeeneeeeeeeaaes 130 Power Train Oil Change csceceeseeeeeeeeeees 178 Power Train System Screens Clean 06 181 Rollover Protective Structure ROPS Inspect 185 Every 2000 Service Hours or 1 Year Electro Hydraulic Oil Filter Change 08 143 Engine Mounts and Equalizer Bar Inspect 147 Hydraulic System Oil Change eee 169 Ladder Hinge Oil Change s es 175 Track Roller Frame Inspect 00 eeee 189 Track Roller Frame Guides Inspect 189 Every Year Cooling System Coolant Sample Level 2 Obtains S EE EEE E 140 Engine Air Filter Primary and or Secondary Element Clean Replace inerea aeaaeai apaatia 144 Every 2 Years Refrigerant Dryer Replace n 184 Every 3 Years Seat Belt Replace c cccccceceeeeeceeesseeereeeees 186 Every 4000 Service Hours Electronic Unit Injector Inspect Adjust 143 Engine Mounts and Crankshaft Vibration Damper INSPeOCt wee Made een 146 Engine Valve Lash Check Adjust eeee 153 Engine Valve Rotators Inspect cee 154 Every 6000 Service Hours Fuel Lines Replace cceceeeeeeeceeceeeeeeeeeeees 158 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 139 Cooling System Water Temperature Regulator ReplaCe EE E cect E EE EA 1
90. s are scheduled for Every 4000 Service Hours Check the valve bridge before setting the valve lash Ensure that the valve bridge is seated equally on both valve stems Adjust the valve bridge before setting the valve lash NOTICE Operation of Caterpillar engines with improper valve adjustments will reduce engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life Electrical shock hazard The electronic unit injec tor system uses 90 120 volts 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 154 Maintenance Section Engine Valve Rotators Inspect SEBU8135 10 Illustration 202 g02819956 A Inlet Valves B Exhaust Valves An adjustment is not required if the valve clearance settings are within 0 08 mm 003 inch of the nominal clearance Set the clearance that is given in the chart if the clearance is not within the limits Table 20 VALVE CLEARANCE SETTING CHART 0 38 mm 0 015 inch 0 76 mm 0 030 inch Inlet Valve Exhaust Valve Refer to your machine Service Manual or your Cat dealer for the complete valve adjustment procedure 103952000 Engine Valve Rotators Inspect SMCS Code 1109 040 When inspecting the valve rotators protec
91. seal on the new filter Install the new engine oil filter element by hand Note Instructions for the installation of the filters are printed on the side of each Caterpillar spin on filter For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter Illustration 201 g01230331 7 Remove the oil filler cap 2 Fill the crankcase with new oil See Operation and Maintenance Manual Capacities Refill Clean the oil filler cap and install the oil filler cap 8 Always measure the oil level with dipstick 1 in order to ensure that the correct amount of oil was added 9 On the dipstick always maintain the oil level in the SAFE OPERATING RANGE zone Reference See Operation and Maintenance Manual Engine Oil Level Check 10 Close the engine access door 104715529 Engine Valve Lash Check Adjust SMCS Code 1102 025 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 Initial wear and seating of valve train components require an initial valve lash adjustment Initial valve lash adjustment for new engines and for rebuilt engines is scheduled at the First 500 Service Hours Engine Oil and Filter Change should also be performed at that time Subsequent valve lash checks and adjustment
92. speed oil change Use a 126 7538 Nozzle Assembly The high speed oil change 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 Illustration 245 g01181288 2 If the high speed oil change system is not used 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 3 Turn the swivel or pipe clockwise in order to open the internal drain valve Allow the oil to drain into a suitable container 4 Remove the swivel or remove the pipe from the drain in the bevel gear case The drain valve will close 5 Clean the oil drain plugs and install the oil drain plugs 6 Change the filter element See Operation and Maintenance Manual Power Train Oil Filter Replace hI TT i H l PERENE Bee aH Illustration 246 g02173590 7 Open the left engine compartment for the transmission oil filler cap 8 Remove the transmission oil filler cap 2 SEBU8 135 10 179 Maintenance Section Power Train Oil Filters Replace 9 Add oil To determine the correct amount of oil see Operation and Maintenance Manual Capacities Refill 10 Clean the transmission oil filler cap and install the
93. t Tilt the aftercooler cores backward toward the engine in order to clean the cores properly Blow out the cores with compressed air Move the air nozzle in a systematic pattern so that the air flow covers the whole core that includes areas in the corner Clean the middle space between the aftercooler core and the a c condenser core Use a bent copper tube that is approximately 1 4 3 8 inch diameter as an extension to the air nozzle This will facilitate cleaning of the middle spaces Do not use steam or high pressure water for cleaning frequently If steam or high pressure water is required to dislodge any debris that is held deep in the cores make sure that the cleaning is thorough This may require partial removal or total removal of the air conditioner condenser for better access Incomplete cleaning with water may cause remaining debris to harden in place Use lights and wire probes in order to ensure that the cleaning is thorough and complete If the debris has hardened in the center of the cores these cores may need to be removed for thorough cleaning If you use a degreaser and steam for removal of oil and grease wash the core with detergent and hot water Thoroughly rinse the core with clean water Dry the cores completely before operating the machine in the work mode Dry If steam or water is used to clean the cores make sure that the cores are completely dry before the track type tractor is put back to work Use
94. t sound make the necessary repairs before you operate the machine 103898104 Hoses and Clamps Inspect Replace SMCS Code 7554 040 7554 510 Inspect the Hoses and the Clamps The nonmetallic hoses and the clamps must be inspected periodically in order to ensure safe operation and continuous operation of the engine fuel system Take proper safety precautions before inspecting or replacing hoses and clamps Note Always use a board or cardboard when the engine components are checked for leaks Leaking fluid that is under pressure can cause serious injury or possible death This proceeding includes leaks that are the size of a pin hole Refer to Operation and Maintenance Manual General Hazard Information for more information Nonmetallic Fuel Lines Note Make sure that the hoses do not contact nearby components Contact with other surfaces will produce chafing that could lead to a leak A properly installed hose will contact only the hose clips 168 SEBU8135 10 Maintenance Section Hoses and Clamps Inspect Replace TOP VIEW OF ENGINE Illustration 226 902141367 1 Rear low pressure fuel lines 2 Front low pressure fuel lines Inspect hoses 1 2 of the engine fuel system for the e Outer covering that is ballooning locally following conditions e Flexible part of the hose that is kinked or crushed Replace any hose which exhibits any of the followi
95. 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 176 Maintenance Section Oil Renewal System Oil Add SEBU8135 10 102849305 Oil Renewal System Oil Add If Equipped SMCS Code 1348 538 1 Park the machine on level ground Lower the attachment to the ground Engage the parking brake and turn off the engine 2 Open the access door on the left side of the cab that is in front of the hydraulic tank Illustration 238 g01420268 3 In order to fill the ORS manually add SAE10W30 oil through the filler tube 1 until sight g
96. the fuel system Reference Refer to Operation and Maintenance Manual Fuel System Prime for more information 102857909 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes Personal injury can result when using cleaner sol vents To help prevent personal injury follow the instruc tions and warnings on the cleaner solvent contain er before using SEBU8 135 10 163 Maintenance Section Fuel System Secondary Filter Replace Personal injury or death can result from a fire Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts 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 com
97. thin 3 years from the year of manufacture as indicated on belt webbing label buckle housing or installation tags non retractable belts 1 2 elie ioe 4 Illustration 265 g01152685 Typical Example 1 Date of installation retractor 2 Date of installation buckle 3 Year of manufacture tag fully extended Web 4 Year of manufacture underside buckle Consult your Cat dealer for the replacement of the seat belt and the mounting hardware Determine age of new seat belt before installing on seat A manufacture label is on belt webbing and imprinted on belt buckle Do not exceed install by date on label Complete seat belt system should be installed with new mounting hardware Date of installation labels should be marked and affixed to the seat belt retractor and buckle Note Date of installation labels should be permanently marked by punch retractable belt or stamp non retractable belt If your machine is equipped with a seat belt extension also perform this replacement procedure for the seat belt extension 103967449 Torque Converter Scavenge Screen Clean SMCS Code 3101 070 MGS 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 a
98. tion 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 This machine is equipped with an engine that meets EPA Tier 2 Euro Stage Ill or MOC Step 3 emission regulations A 500 hour engine oil change interval is possible if the following conditions are met Accept able operating conditions recommended multigrade oil types and an S O S oil sampling and analysis pro gram are used Otherwise use a 250 hour oil change interval If you select an interval for oil and filter change that is too long you may damage the engine CAT oil filters are recommended Recommended multigrade oil types are listed in Table 19 Note Do not use API CF 4 oils in Caterpillar machines with diesel engines Abnormally harsh operating cycles or harsh environments can shorten the service life of the engine oil Arctic temperatures corrosive environments or dusty conditions may require a reduction in engine oil change intervals from the recommendations in Table 19 Also refer to Manual SEBU5898 Cold Weather Recommendations for all Caterpillar Machines Poor maintenance of air filters or of fuel filters requires reduced oil change intervals See your Cat dealer for more information if this product will experience abnormally harsh operating cycles or harsh environments 152 Maintenance Sect
99. tive glasses or face shield and protective clothing must be worn to prevent being burned by hot oil or spray Caterpillar recommends replacing valve rotators that are operating improperly An improperly operating valve rotator will shorten valve life because of accelerated wear on the valves Also metal particles from a damaged valve rotator could fall into the cylinder and damage to the piston head and to the cylinder head may result Illustration 203 g00882731 Start the engine and run the engine at low idle Watch the top surface of each valve rotator Whenever an inlet valve closes or an exhaust valve closes each valve rotator should turn If a valve rotator fails to turn consult your Cat dealer for service 102858027 Equalizer Bar End Pins Oil Level Check SMCS Code 7206 535 FLV g01424066 Illustration 204 SEBU8135 10 155 Maintenance Section Ether Starting Aid Cylinder Replace g01300275 Illustration 205 Instruction film on front of the lubricant reservoir for the equalizer bar Illustration 206 g01300316 Top view The lubricant reservoir is located outside of the cab in a compartment on the left side of the machine The reservoir is near the refrigerant dryer Remove the oil filler cap with the tee handle in order to add the oil to the lubricant reservoir Note If one side of the reservoir is lower than the other side maintenance of the equalizer bar is
100. transmission oil filler cap OIL AT OPERATING TEMP Y OPR ZONE 30L gt ENGINE STOPPED COLD OIL YY OPR ZONE 30L Illustration 247 g006 11366 11 Maintain the oil level in the OPR ZONE on the dipstick 1 Close the access door 103653852 Power Train Oil Filters Replace SMCS Code 3067 510 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo 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 Replace the filter elements if the transmission oil filter indicator comes on during operation One transmission oil filter is located under the walkway on the left side of the machine The other transmission oil filter is located under the walkway on the right side of the machine Remove the floorplates Perform the following steps for each transmission oil filter 1 Remove the filter housing drain plug The filter housing drain plug is located at th
101. ue to belt slippage indicates that the belt tensioner possibly needs to be replaced 5 Close the engine access door 6 Turn the battery disconnect switch to the ON position Replace the Belt 1 Replace the belt if any of the following conditions exist e excessive cracking e excessive wear e excessive damage 2 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 3 Turn the battery disconnect switch to the OFF position 132 Maintenance Section Braking System Test SEBU8135 10 Remove the Belt 1 Remove the floorplate bolts and open the manhole cover that is located in the cab g01228297 Illustration 156 2 Remove eight bolts 8 from coupling guard 10 as shown Remove any hoses that are attached to the guard 3 Loosen top guard 9 and lift the top guard for clearance Do not remove the top guard 4 Insert a 12 7 mm 0 50 inch ratchet into square hole on belt tensioner 6 5 Pry the belt tensioner in a counterclockwise direction in order to remove the tension from the belt 6 Remove the belt from the pulleys Install the Belt Note The first spare belt for the first belt replacement is equipped with the machine 1 Loosen the spare belt from the tie down straps that surrounds coupling guard 10 not shown 2 Free the belt from the guard
102. ure 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 Replace Nonmetallic Fuel Lines Make sure to replace the nonmetallic fuel lines and the rubber grommets at 6000 service hours SEBU8135 10 159 Maintenance Section Fuel Lines Replace TOP VIEW OF ENGINE Illustration 212 g02141035 Top view of engine 2 Remove the front two low pressure fuel lines 2 NOTICE and install new fuel lines and rubber grommets Keep all parts clean from contaminants Reference Refer to the Engine Disassembly Contaminants may cause rapid wear and shortened and Assembly for information on removing and component life installing the fuel lines Note Make sure that the hoses do not contact 1 Remove the two rear low pressure fuel lines 1 nearby components Contact with other surfaces will and install new fuel lines and rubber grommets produce chafing that could lead to a leak A properly installed hose will contact only the hose clips 1

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