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MAINTENANCE INTERVALS - Safety

1. Amount of Caterpillar ELC Extender by Cooling System Capacity Recommended Amount of Caterpillar Extender 65 to 83 L 17 to 22 US gal 1 60 L 54 oz 1 The cooling system capacity for the D7R is 75 L 19 8 US gal Cooling System Capacity When a Caterpillar Extended Life Coolant ELC is used an extender must be added to the cooling system See the Operation and Maintenance Manual Maintenance Interval Schedule for the proper service interval The amount of extender is determined by the cooling system capacity For additional information about adding an extender see Operation and Maintenance Manual Coolant Recommendations or consult your Caterpillar dealer Extended Life Coolant ELC Additive Illustration 172 g00588487 1 The filler cap is located inside the access door on the top left side of the radiator guard Slowly loosen the filler cap in order to relieve the pressure Remove the cap 2 Add ELC Drain some coolant from the radiator into a suitable container in order to allow space for the extra ELC Note Always discard drained fluids according to local regulations 3 Start the engine Run the engine without the filler cap until the thermostat opens and the coolant level stabilizes Check for leaks 4 Check the coolant level If necessary add premixed coolant in order to correct the coolant level Maintain the coolant level between area 2 and area 3 of the fi
2. Remove the drain plug on the bottom of the winch Allow the oil to drain into a suitable container Inspect the plug seal If necessary replace the plug seal Clean the drain plug and install the drain plug Fill the oil compartment until oil is visible in the sight gauge See Operation and Maintenance Manual Refill Capacities 6 Clean the filler plug and install the filler plug Run the engine at low idle Maintain the oil level so that the oil level is visible in the sight gauge Illustration 258 900039952 8 Remove the breather on top of the winch case Wash the breather in a clean nonflammable solvent Install the breather 100038229 Winch Oil Level Check SMCS Code 5163 535 FLV Illustration 259 900039951 When the engine is at low idle the oil should be visible in the sight gauge 900039947 Illustration 260 131 Maintenance Section Winch Oil Level Check Remove the oil filler plug If necessary add oil through the oil filler cap Check for oil leaks around the covers and around the hoses Repair any oil leaks 101381183 Winch Wire Rope Install SMCS Code 5163 012 If equipped Personal injury or death can result from worn wire rope cable Worn or frayed cable could break causing injury Check the wire rope cable If cable is worn or is frayed install a new cable PA57VS The cable is attached to the drum on the winch with a cable ferrule Th
3. Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Operate the engine in order to warm the oil Park the machine on level ground Lower all implements to the ground Apply slight downward pressure Engage the parking brake switch Stop the engine Some machines may be equipped with ecology drain valves 900103783 Illustration 241 1 Remove the transmission oil drain plug Drain the oil into a suitable container 2 Clean the transmission oil drain plug and install the transmission oil drain plug 3 Change the filter element See Operation and Maintenance Manual Transmission Oil Filter Replace 4 Clean the transmission magnetic screen See Operation and Maintenance Manual Transmission Magnetic Screen Clean 5 Open the access cover for the transmission oil filler cap The access cover is on the right fender of the machine 125 Maintenance Section Transmission Oil Filter Replace 900602393 Illustration 242 6 Remove the transmission oil filler cap 7 Add oil To determine the correct amount of oil see Operation and Maintenance Manual Refill Capacities 8 Clean the transmission oil filler cap and install the transmission oil filler cap 9 Maintain the oil level to the FULL mark on the dips
4. 1 Open the left engine access door The ether starting aid is located on the left front of the engine 2 Loosen the oylinder retaining clamp Unscrew the empty ether starting aid cylinder and remove the empty ether starting aid cylinder 3 Remove the used gasket Install the new gasket that is provided with each new ether starting aid cylinder 4 Install the new ether starting aid cylinder Tighten the ether starting aid cylinder by hand Tighten the cylinder retaining clamp securely 5 Close the engine access door 106 Maintenance Section Fan Drive Pulley and Idler Lubricate Fan Drive Pulley and Idler Lubricate SMCS Code 1359 086 900671267 Illustration 193 Lubricate two fittings with Bearing Lubricant Special Purpose Grease SPG The fittings are for the fan drive pulley and for the idler belt tightener 100803315 Final Drive Oil Change SMCS Code 4050 535 FLV Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect
5. 3 Desiccant 4 tracer dye wafer 5 Quick disconnect fitting for the INLET hose 1 Stop the engine Allow the air conditioning System to remain inactive for five minutes in order to equalize the pressure 2 Disconnect the INLET hose from quick disconnect fitting 5 on the old dryer 3 Connect the INLET hose to quick disconnect fitting 5 on the new dryer 4 Add 30 mL 1 ounce of refrigerant oil to the System Note If you install a new air conditioner compressor do not add 30 mL 1 ounce of refrigerant oil to the System 5 Start the engine and operate the air conditioning System for one minute in order to evacuate the refrigerant from the used dryer 6 With the air conditioning system in operation disconnect the OUTLET hose from quick disconnect fitting 1 on the old dryer 7 Stop the engine The air conditioning system must be idle for five minutes in order to equalize the pressure 8 Connect the OUTLET hose that was disconnected in Step 6 to quick disconnect fitting 1 on the new dryer Also refer to the replacement procedure in the Service Manual Module SENR 5664 Air Conditioning and Heating Compliance with this procedure will provide the following benefits e The refrigerant compressor oil will not escape from the system 88 Maintenance Section Air Conditioner System Check Replace e The amount of moisture that enters the system will be reduced e A sludge deposit will
6. Inspect SMCS Code 7206 040 PN 7207 040 PN Illustration 190 900104571 Check the equalizer bar pins for looseness and for unusual wear If unusual wear is evident see the Service Manual or consult your Caterpillar dealer for an inspection and for repair instructions i01398945 Equalizer Bar Pins Lubricate SMCS Code 7206 086 PN 7207 086 PN NOTICE Apply lubricant to the fittings with a hand operated grease gun only Use of pressure operated lubricating equipment damages the seals The equalizer bar has two vent passages in the outside positions The equalizer bar has one grease fitting in the center 900104584 Illustration 191 105 Maintenance Section Equalizer Bar Pins Inspect Remove the large plug in order to provide access to the grease fitting Apply Caterpillar Gear Oil GO Apply the gear oil through the fitting until gear oil squirts out of one vent passage or out of both vent passages Use a hand operated grease gun to apply the grease Note If it is difficult to use the gear oil due to current maintenance practices you can use Caterpillar Multipurpose Grease MPGM Because the gear oil has greater load carrying capacity and better lubricating characteristics the gear oil is used at the factory The combination of gear oil and MPGM is not harmful to the machine 100080065 Ether Starting Aid Cylinder Replace SMCS Code 1456 510 CD Illustration 192 900104559
7. Start the engine Operate the engine at HIGH IDLE Illustration 150 g00104078 2 Set the air conditioner control for maximum cooling Set the fan speed switch knob to the HIGH position 3 To stabilize the air conditioning system run the air conditioning system for two minutes 4 Check for refrigerant in the system Feel the suction line and the discharge line If the system contains refrigerant the discharge line is warmer than the suction line If the system does not contain refrigerant or the system contains only a small amount of refrigerant poor cooling will result 5 Stop the engine Air Conditioner Belt Inspect Adjust Replace If equipped SMCS Code 1357 025 1357 040 1357 510 Inspect 1 Inspect the condition of the compressor drive belt The belt should deflect 14 to 20 mm 56 to 81 inch under 110 N 25 Ib of force Use a 144 0235 Belt Tension Gauge in order to measure the tension Adjust Replace 1 Loosen compressor mounting bolts 1 and 2 2 Loosen adjusting bracket nuts 3 3 To achieve the correct belt tension move the compressor inward or move the compressor outward Tighten adjusting bracket nuts 3 Tighten compressor mounting bolts 1 and 2 Recheck the belt adjustment 4 If necessary repeat Step 1 to Step 3 Note Use the same procedure in order to replace the belt i01321512 Air Conditioner I
8. for the complete procedure for cleaning the radiator core 118 Maintenance Section Radiator Pressure Cap Clean Replace 100058123 Radiator Pressure Clean Replace SMCS Code 1353 070 Z2 1353 510 42 Illustration 222 900100622 1 Slowly remove the radiator cap in order to relieve system pressure 2 Inspect the radiator cap for damage for deposits or for foreign material Clean the radiator cap with a clean cloth Replace the radiator cap if the radiator cap is damaged 3 Install the radiator cap 100072383 Recoil Spring Compartment Cil Level Check SMCS Code 4158 535 Hot oil and components can cause personal in jury Do notallow hot oil or components to contact skin 1 Remove the cover plate for the oil filler Illustration 223 900100922 2 Maintain the oil level to the level mark on the dipstick 3 Install the cover plate 4 Repeat the procedure for the other recoil compartment 100072976 Ripper Linkage and Cylinder Bearings Lubricate SMCS Code 6313 086 BD L4 Illustration 224 900103773 Lubricate eleven grease fittings 100925689 Ripper and Shank Protector Inspect Replace SMCS Code 6808 040 6808 510 6810 6812 040 6812 510 If equipped Illustration 225 900550432 When the ripper tip is worn close to the shank replace the ripper tip When the shank protector is worn close to the shank replace the shank protect
9. Always wear protective glasses when working with batteries Turn the engine start switch key to the OFF position Turn all of the switches to the OFF position N Turn the battery disconnect switch to the OFF position Remove the key Make notes or mark the arrangement of the cables and of the batteries for correct installation 92 Maintenance Section Brakes Indicators and Gauges Test 900738611 Illustration 160 Typical example of the battery box compartment 1 Battery disconnect switch 2 Positive cable 3 Positive cable terminal 4 Negative cable terminal 5 Negative cable Serre aS Note Typical negative cables and covers for negative terminals are black 4 Always disconnect the negative cable at the negative cable terminal first in order to prevent a spark Verify that this negative cable is connected to the battery disconnect switch Note Some positive cables and some covers for positive terminals are red for correct identification 5 Disconnect the positive cable at the positive cable terminal 6 Replace the disconnect switch the battery cables or the batteries as required 7 Connect the positive cable at the positive cable terminal 8 Always connect the negative cable at the negative cable terminal last 9 Install the key and turn the battery disconnect switch to the ON position Recycle the Battery Always recycle a battery Never discard a batte
10. Bits Inspect Replace SMCS Code 6801 040 6801 510 6804 040 6804 510 U Illustration 176 900104458 1 Raise the bulldozer blade and block up the bulldozer blade When you remove the cutting edges and the end bits maintain the bulldozer blade at a minimum height 2 Remove the bolts Then remove the cutting edge and the end bits 3 Thoroughly clean all contact surfaces 4 Inspect the opposite side of the cutting edge If the opposite side of the cutting edge is not worn turn the opposite side of the cutting edge outward and install the cutting edge 5 f both sides of the cutting edge are worn install a new cutting edge section 6 Repeat Step 4 and Step 5 for the end bits 99 Maintenance Section Cutting Edges and End Bits Inspect Replace 7 Install all bolts and tighten the bolts to the specified torque Refer to Operation and Maintenance Manual Torques for Ground Engaging Tools 8 Strike the bolt heads with a hammer that weighs 1 4 kg 3 Ib Tighten the bolts to the specified torque again 9 Raise the bulldozer blade and remove the blocking Lower the bulldozer blade to the ground i01364960 Engine Air Filter Primary Element Clean Replace SMCS Code 1051 070 1051 510 PY 1054 070 PY 1054 510 PY 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 eleme
11. Remove the hose from the breather cover 2 Loosen the breather inlet hose clamp Remove the engine crankcase breather 3 Check the condition of the cover seal Replace the cover seal if the cover seal is damaged 4 Wash the breather element and the breather element cover assembly in a clean nonflammable solvent 5 Shake the breather element until the breather element is dry You may also use pressure air to dry the breather element 6 Check the condition of the hose Replace the hose if the hose is damaged 7 Install the breather element cover assembly 8 Install the hose and the breather outlet hose clamps 9 Install the access cover i01365509 Engine Oil Level Check SMCS Code 1302 535 FLV 1326 535 FLV Hot oil and components can cause personal in jury Do notallow hot oil or components to contact skin NOTICE Do not under fill or overfill engine crankcase with oil Either condition can cause engine damage 1 The level gauge relies on gravity The machine must be on a level surface for an accurate check 2 Open the access cover that is on the left side of the machine 900103739 Illustration 186 3 Check the SAFE OPERATING RANGE side of the dipstick 1 while the engine is running and the oil is at operating temperature Maintain the oil level in the crosshatch on the dipstick Check the SAFE STARTING RANGE side of dipstick 1 while the engine is stopped The oil should
12. and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates g00100627 Illustration 194 1 Position one final drive so that oil level mark 1 is horizontal The drain plug 3 will point downward 2 Remove drain plug 3 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 Fill the final drive with oil to the bottom of the filler plug opening See Operation and Maintenance Manual Refill Capacities 7 Inspect the condition of the seal of the filler plug Replace the plug seal if the plug seal is damaged 8 Repeat Step 1 to Step 7 in order to change the oil in the other final drive 101023410 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 900100625 Illustration 195 1 Position one final drive so that oil level mark 1 is horizontal and drain plug 3 is at the bottom 2 Remove oil filler plug 2 3 The oil level should be at the bottom of the filler plug opening Add oil if necessary See the Table in the article Lubricant Viscosities for the type of oil 4 Install oil filler plug 2 5 Repeat Step 1 to Step 4 in order to check the
13. and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates 900463007 Illustration 212 1 The hydraulic tank is on the right side of the machine Slowly remove the hydraulic tank filler cap in order to relieve the system pressure 115 Maintenance Section Hydraulic System Oil Level Check 900104435 Illustration 213 000463709 Illustration 214 2 Open the access door that is on top of the 13 Maintain the hydraulic oil to the FULL mark in hydraulic tank Also open the access door that the sight gauge is on the side of the hydraulic tank 3 Remove filter group 1 and properly discard 00908319 filter group 1 Remove filter group 2 with Hydraulic System Oil Level wrench Remove the filter element and properly discard the filter element Check 4 Wash the housing for filter group 2 in clean SMCS Code 5056 535 FLV 7479 nonflammable solvent Clean the filter bases with a clean cloth in order to remove all of the old filter seals At operating temperature the hydraulic tank is hot 5 Install a new filter element in filter group 2 and under pressure App
14. bumping or tap ping the filter elements Do not use filter elements with damaged pleats gaskets or seals Do not wash the fil ter elements 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 9 Install a clean primary filter element Write the date of service on the element 10 Clean the cover and install the cover 11 Close the access door if equipped Illustration 181 900103729 12 Reset the filter element indicator Start the engine If the yellow piston in the filter element indicator moves into the red zone install a new primary filter element Also if the exhaust smoke is black install a new primary filter element 100078414 Engine Air Filter Secondary Element Replace SMCS Code 1051 510 SE 1054 510 SE NOTICE Always replace the secondary element Do not at tempt to reuse it by cleaning Engine damage could result Note Replace the secondary filter element when you service the primary element for the third time If a clean primary element has been installed and the filter element indicator still enters the red zone replace the secondary filter element Also if the exhaust smoke remains black and a clean primary filter element has been installed replace the secon
15. capacity fuse that was removed Otherwise electrical damage could result NOTICE If itis necessary to replace fuses frequently an elec trical problem may exist Contact your Caterpillar dealer CU do 6 a0 Uu Illustration 207 900103744 D amp O 0 Cigar Lighter 1 10 Amp Electrical Power for Cab 2 10 Amp Key Start Switch 3 10 Amp Air Conditioner 4 20 Amp Electronic Clutch Brake 5 10 Amp Windshield Wiper Washer 6 15 Amp Caterpillar Monitoring System Panel 7 10 Amp Auxiliary Circuit 8 10 Amp Directional Control 9 10 Amp Flood Lights 10 10 Amp Brake System 11 10 Amp Horn 12 10 Amp Dump Valve 13 10 Amp i01032547 Horn Test SMCS Code 7402 081 900545735 Illustration 208 Push the switch downward in order to sound the forward horn 100907501 Hydraulic System Oil Change SMCS Code 5050 044 At operating temperature the hydraulic tank is hot and under pressure Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand Remove the filler cap slowly to relieve pressure
16. ee Seaven Screen CI eet Ce s Engine Crankcase Breather Clean 102 inch Wie 5 131 Fuel System Primary Filter Replace 109 Window Washer Reservoir Fill T 132 Fuel System Secondary Filter Replace 110 poer Fuel Tank Cap Filter and Strainer Window Wipers Inspect Replace 132 Replace Clean 111 A Hydraulic System Oil Filter Replace 114 Every 10 Service Hours or Daily Recoil Spring Compartment Oil Level Check 118 Transmission Oil Filter Replace 125 Backup Alarm 90 Brakes Indicators and Gauges Test 92 Winch Filter and Magnetic Strainer Cab Filter Fresh Air Clean Inspect Replace MS 94 Replace Clean 129 Cooling System Level Check 97 J Engine Oil Level S OBS EE 103 Every 1000 Service Hours or 6 Months bs od Primary Filter Water Separator 108 Lift Cylinder Yoke Bearings Lubricate 116 Beets Hate Ss Sele sets SE ee eS Cae ete MUCH DIDI Rollover Protective Structure ROPS Inspect 119 edi bo SCONE NN iiaae E Torque Converter Scavenge Screen Clean 120 Hydraulic System Oll Level Cheik oci cs 115 Transmission Magnetic Screen Clean 124 Seal
17. frame GF Illustration 239 900039582 If the dimension X is less than 71 5 mm 2 81 inch replace the track roller frame guides Consult your Caterpillar dealer for information or for service i01146867 Transmission Magnetic Screen Clean SMCS Code 3030 070 MGS When you change the transmission oil clean the magnet assembly and the screen Illustration 240 g00103746 1 Remove the bottom guard for access to the screen group 2 Remove the nuts which hold the cover to the housing 3 Remove the screen and the magnet assembly from the housing 4 Wash the screen and the magnet assembly in a clean nonflammable solvent 5 Inspect the seal If the seal is damaged install a new seal 6 Install the screen and the magnet assembly 7 Install the cover on the screen housing 8 Install the bottom guard 101137803 Transmission Oil Change SMCS Code 3030 3080 044 A WARNING Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids
18. if necessary repair the service brake before returning the machine to operation i01400166 Cab Filter Fresh Air Clean Inspect Replace If Equipped SMCS Code 7342 070 Fl 7342 510 FI 000737776 Illustration 163 1 Remove the filter cover and the filter element The filter cover is in front of the cab 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 Note Clean the filters more often in dusty conditions i01400226 Cab Filter Recirculation Clean Inspect Replace If Equipped SMCS Code 7342 040 7342 070 7342 510 900737786 Illustration 164 1 Remove the filter element that is positioned in the operator s compartment 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 Note Clean the filters more often in dusty conditions 100753322 Circuit Breakers Reset SMCS Code 1417 529 1420 529 900339673 Illustration 165 T
19. located in the front bottom guard 900737503 Illustration 169 3 Place the drain hose through the pipe plug opening 4 Open the drain valve Allow the coolant to drain into a suitable container 96 Maintenance Section Cooling System Extended Life Coolant Extender Add 5 Flush the system with water Flush the system until the draining water is clear Note If the cooling system is already using ELC cleaning agents are not required to be used at the specified coolant change interval Cleaning agents are only required if the system has been contaminated by the addition of some other type of coolant or by cooling system damage Clean water is the only cleaning agent that is required when ELC is drained from the cooling system Note If you change to an ELC from another type of coolant use a Caterpillar cleaning agent to flush the cooling system After you drain the cooling system thoroughly flush the cooling system with clean water All of the cleaning agent must be removed from the cooling system Refer to the Topic Extended Life Coolant ELC in this manual 6 Close the drain valve and install the plug 7 Add the ELC solution See the following topics in this publication e Cooling System Specifications e Refill Capacities Note Caterpillar antifreeze contains additive If you are using Caterpillar antifreeze do not add the supplemental coolant additive at this time Also do not change the supple
20. of the rear window 133 Maintenance Section Windows Clean
21. of the front roller frame relative to the rear roller frame 900427478 Illustration 235 Typical example 1 Raise the front of the machine Place a 100 mm 4 inch block under the outside edge of a track grouser Place the block near the front track idler Lower the machine onto the block 123 Maintenance Section Track Roller Frame Guides Inspect Illustration 236 99041475 Typical example 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 Illustration 237 900427479 Typical example 3 Raise the front of the machine Place the block under the inside edge of the same track grouser Lower the machine onto the block Illustration 238 Typical example 124 Maintenance Section Transmission Magnetic Screen Clean 4 Put a mark on the tubular section of the front roller frame This mark should correspond with the mark on the rear roller frame Measure the distance between the two marks on the front roller frame If the distance between the two marks is greater than 4 5 mm 18 inch inspect the track roller frame guides for wear Repeat the entire procedure for the other side of the machine NOTICE Never build up the track roller frame guides with hard face welding This will cause serious wear damage to the guide slots in the front track roller
22. reinforcement plates to the ROPS in order to straighten the ROPS Do not weld reinforcement plates to the ROPS in order to repair the ROPS If the ROPS has any cracks in the welds in the castings or in any metal section consult your Caterpillar dealer for repairs 120 Maintenance Section Seat Belt Inspect 100038410 Seat Belt Inspect SMCS Code 7327 040 Illustration 227 900040782 Always check the condition of the seat belt and the condition of the belt mounting hardware before you operate the machine Inspect the belt mounting hardware Replace any belt mounting hardware that is damaged or worn Regardless of the appearance replace the seat belt once during every three year interval 100073972 Torque Converter Scavenge Screen Clean SMCS Code 3101 070 MGS 3105 When you change the transmission oil clean the torque converter scavenge screen 1 Remove the bottom guard in order to gain access to the torque converter 2 Disconnect the hose from the torque converter housing Illustration 228 900104059 3 Remove the screen from the torque converter housing 4 Wash the screen in a clean nonflammable solvent 5 Install the screen in the torque converter housing 6 Connect the hose to the torque converter housing 7 Install the bottom guard i01400449 Track Adjustment Adjust SMCS Code 4170 025 A WARNING Grease is under high
23. than 30 cc 1 oz of water weekly This usage of water is typical with the proper charging rate and with a moderate climate When you are operating the machine in extreme temperatures check the water in the battery cells weekly 1 Open the battery access covers The battery access covers are located on the left side of the machine outside the operator compartment 2 Inspect the electrolyte level in each battery cell A maintenance free battery does not require inspection Maintain the electrolyte level to the bottom of the filler openings Use distilled water If distilled water is not available use clean drinking water 3 Close the battery access covers 91 Maintenance Section Battery Electrolyte Level Check 101371301 Battery Battery Cable or Battery Disconnect Switch Replace SMCS Code 1401 510 1402 510 1411 510 A WARNING Batteries give off flammable fumes which can ex plode To avoid injury or death do not strike a match cause a spark or smoke in the vicinity of a battery A WARNING Personal injury can result from battery fumes or explosion Batteries give off flammable fumes that can ex plode Electrolyte is an acid and can cause per sonal injury if it contacts the skin or eyes Prevent sparks near the batteries Sparks could cause vapors to explode Do not allow jumper ca ble ends to contact each other or the engine Im proper jumper cable connections can cause an ex plosion
24. tight or too loose see Operation and Maintenance Manual Track Adjustment Adjust i01123943 Track Pins Inspect SMCS Code 4175 040 PN Fingers can be burned from hot pins and bush ings The pins and bushings in a dry joint can become very hot It is possible to burn the fingers if there is more than brief contact with these components Use the recommendations in order to extend the life of the undercarriage Use the recommendations in order to avoid excessive downtime 1 During the machine operation listen for unusual squeaking and for unusual squealing This can indicate a dry joint 2 Check the machine for dry joints weekly Check for dry joints 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 dealers Custom Track Service expert can perform track inspection i01024746 Track Roller Frame Guides Inspect SMCS Code 4177 040 Measure the rotational movement
25. 00104001 Illustration 232 2 Add multipurpose grease MPGM through track adjustment valve 5 Add the MPGM until dimension 2 is correct 3 Operate the machine back and forth in order to equalize the pressure Allow the machine to coast to a complete stop Do not use the brakes 4 Remeasure dimension 2 122 Maintenance Section Track Adjustment Check Tight Track Adjustment 900104002 Illustration 233 1 Remove the access cover 2 Loosen relief valve 6 by one turn of 360 degrees Allow the grease to escape 3 Close the relief valve 4 Add MPGM through track adjustment valve 5 Add grease until dimension 2 is correct 5 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 6 Remeasure dimension 2 Repeat Steps 4 and 5 until dimension 2 is correct 7 Install the access cover Bolt Torque for Track Shoes The torque requirement for track shoe bolts is 400 70 N m 300 50 Ib ft Tighten the bolts for an additional 120 degrees If you are using bolts with a master link tighten the bolts to a torque of 400 70 N m 300 50 Ib ft Then tighten the bolts for an additional 180 degrees 100078416 Track Adjustment Check SMCS Code 4170 535 900104399 Illustration 234 Check the track adjustment Check the track for wear and for excessive dirt buildup If the track appears to be too
26. Circuit Breakers Reset 94 Angle Blade Manual Tilt Brace Lubricate 90 Cutting Edges and End Bits Inspect Replace 99 S Inspect PERE E A N ATE EA O T 90 Engine Air Filter Primary Element Braking System 93 Clean Replace 99 Engine Oil and Filter Change 103 Engine Air Filter Secondary Element Replace 101 Equalizer Bar Pins Lubricate ME 105 Engine Air Precleaner Clean 102 Fan Drive Pulley and Idler Lubricate 106 Equalizer Bar Pins Inspect 105 Final Drive Oil Level 106 Ether Starting Aid Cylinder Replace 105 Track Adjustment Adjust 120 Front Idler Position 107 Track Adjustment Check 122 Fuel System Prie t ehe 107 Fuses Replace nennen 112 Initial 500 Service Hours Oil Filter Inspect ssesseeeeereene 116 Radiator core Clean emi 117 Transmission Oil Filter Replace 125 Radiator Pressure Cap Clean Replace 118 Ripper Tip Shank Protector Inspect Every 500 Service Hours or 3 Months
27. Inspector 0 Transmission OM adeundi 12 Sransmissonlbevelecchedes 127 Winch Oil Change 130 Winch Oil Level Check nS 181 Every 2000 Service Hours or 1 Year Windows Clean esee 133 Air Conditioner System Check Replace 88 Engine Valve Lash Check 104 Engine Valve Rotators Inspect 104 Final Drive Oil Change 106 Hydraulic System Oil Change 113 Track Roller Frame Guides Inspect 123 Every Year Air Conditioner In Line Dryer Replace 87 Every 3000 Service Hours or 2 Years Cooling System Extended Life Coolant Extender 96 Cooling System Water Temperature Regulator i e C 98 Every 6000 Service Hours or 4 Years Cooling System Extended Life Coolant Change 95 85 Maintenance Section Maintenance Interval Schedule 86 Maintenance Section Air Conditioner Test 100074075 Air Conditioner Test SMCS Code 7320 081 A WARNING Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Illustration 149 g00104077 1
28. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved A SEBU6896 03 CATERPILLAR EET Operation ane Maintenance manual 2EN1 U Differential Steering 84 Maintenance Section Maintenance Interval Schedule 101183534 Every 50 Service Hours Weekly Maintenance Interval Schedule Cab Filter Recirculation Clean Inspect alie 94 SMCS Code 7000 Pivot Shaft Oil Level Check 117 Ripper Linkage and Cylinder Bearings Note All safety information warnings and L bDriCate n ere rente eie s 118 instructions must be read and understood before Track Pins 122 you perform any operation or any maintenance procedure Initial 250 Service Hours Before each consecutive interval is performed all Engine Valve Lash Check 104 of the maintenance requirements from the previous Transmission Oil Filter Replace 125 interval must also be performed r Every 250 Service Hours or Monthly When Required Air Conditioner Test 86 Battery Electrolyte Level Check 91 Air Conditioner Belt Inspect Adjust Replace 86 Battery Battery Cable or Battery Disconnect Switch Alternator and Fan Belts Inspect Adjust ar Els Siea NE 91 Replace 89
29. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the machine Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and sup plies suitable to collect and contain fluids in Caterpillar machines Dispose of all fluids according to local regulations and mandates 113 Maintenance Section Horn Test Operate the machine in order to warm the oil Park the machine on level ground Lower the bulldozer blade to the ground and apply slight downward pressure Engage the parking brake and stop the engine 900462980 Illustration 209 1 Remove the hydraulic tank filler cap slowly in order to relieve any pressure 2 Wash the filler strainer and the filler cap in a clean nonflammable solvent 900104433 Illustration 210 3 Remove the oil drain plug The oil drain plug is located under the right rear of the machine 4 Attach a hose to a 1 inch NPT pipe nipple This 1 inch NPT pipe nipple should have a length of 100 mm 4 inch 5 Install the pipe nipple into the drain plug opening 6 Rotate the pipe nipple clockwise in order to open the internal drain valve Allow the oil to drain into a suitable container 7 Remove the pipe nipple
30. SMCS Code 1258 If the engine does not start air may be trapped in the fuel lines to the engine Use the following procedure in order to purge air from the fuel lines Fuel Priming Pump If Equipped The fuel priming pump is located in the engine compartment on the right side of the machine Illustration 197 900103758 108 Maintenance Section Fuel System Primary Filter Water Separator Drain 1 Unlock the priming pump plunger Operate the plunger until you feel resistance 2 Push in the plunger Hand tighten the plunger 3 Start the engine If the engine does not start or if the engine continues to misfire or smoke additional priming is necessary 4 Run the engine at the LOW IDLE position until the engine runs smoothly 101398984 Fuel System Primary Filter Water Separator Drain SMCS Code 1263 543 1263 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 compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Pro
31. The valve for the hydraulic tank will close 114 Maintenance Section Hydraulic System Oil Filter Replace 8 Clean the drain plug and install the drain plug Tighten the drain plug to a torque of 68 7 Nm 50 5 Ib ft 9 See Operation and Maintenance Manual Hydraulic System Oil Filter Replace Change the hydraulic system filter 10 Install the filler strainer 11 See Operation and Maintenance Manual Refill Capacities in order to determine the amount of hydraulic oil that is needed to fill the hydraulic oil tank Fill the hydraulic oil tank 12 Inspect the filler cap gasket Replace the gasket if damage or wear is evident 13 Install the filler cap 14 Start the engine Run the engine for few minutes 900104434 Illustration 211 15 Maintain the oil level to the FULL mark in the sight gauge Add oil if necessary 16 Stop the engine 100907643 Hydraulic System Oil Filter Replace SMCS Code 5068 510 At operating temperature the hydraulic tank is hot and under pressure Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand Remove the filler cap slowly to relieve pressure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting
32. Window Washer The washer fluid lt 7 bottle is on the left side of the operator s compartment Open the access cover Remove the fluid bottle cap in order to fill the washer fluid bottle i01279804 Window Wipers Inspect Replace SMCS Code 7305 040 7305 510 900103881 Illustration 264 Inspect these wiper blades the front the right the left and the rear Replace any wiper blades that are damaged or worn Replace any wiper blades that streak the window i01124791 Windows Clean SMCS Code 7310 070 7340 070 Use commercially available window cleaning solutions to clean the windows To clean the outside of the rear window from the inside of the cab remove the sliding section of the rear window Use the following procedure in order to remove the sliding section of the rear window Illustration 265 900039956 1 Lift latch 1 in order to slide the windows 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 sliding 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
33. a level that is below the thermostat housing NOTICE Failure to replace the engine s thermostat on a regu larly scheduled basis could cause severe engine dam age Note If you are only installing a new thermostat drain the cooling system coolant to a level that is below the thermostat housing LA Illustration 175 900737321 1 Loosen the hose clamp and remove the hose from the elbow Disconnect the hose assembly from the thermostat housing assembly 2 Remove the bolts from the elbow Remove the elbow and the thermostat housing assembly 3 Remove the gasket the thermostat and the seal from the thermostat housing NOTICE A used thermostat can be installed if the thermostat conforms to test specifications and the thermostat is not damaged Do not install a used thermostat that has excessive buildup or deposits NOTICE Since Caterpillar engines incorporate a shunt design cooling system it is mandatory to always operate the engine with a thermostat Depending on load failure to operate with a thermo stat could result in either an overheating or an over cooling condition NOTICE If the thermostat is installed incorrectly it will cause the engine to overheat 4 Install a new seal in the thermostat housing Install a new thermostat and a new gasket Install the thermostat housing on the engine cylinder head 5 Install the elbow and the hose Tighten the hose clamp 100079309 Cutting Edges and End
34. adout shows 188 MPH and km h e The action light stays illuminated e The action alarm sounds once The monitoring panel is then in the normal operating mode If the above tests are not correctly completed the system will not function in the normal operating mode Consult your Caterpillar dealer for an electrical system check Any repairs must be made before you start the engine Turn on all of the machine lights Check for proper operation Sound the forward horn Move the machine forward and test the service brakes See Operation and Maintenance Manual Braking System Test Stop the engine Make any necessary repairs before you operate the machine Braking System Test SMCS Code 4100 081 4267 081 A WARNING If the machine moves during the test reduce the engine speed immediately and engage the park ing brake If the machine moved while testing the brakes consult your Caterpillar dealer for brake inspec tion and repair Damaged brakes must be repaired before returning the machine to operation 93 Maintenance Section Braking System Test Make sure that the area around the machine is clear of personnel and clear of obstacles Test the brakes on a dry level surface Fasten the seat belt before you test the brakes The following test is used to determine whether the service brake is functional This test is not intended to determine the maximum brake holding effort The brake hol
35. be cold Maintain the oil level in the crosshatch on the dipstick Note When you operate the machine on severe slopes the oil level in the engine crankcase must be at the top end of the SAFE STARTING RANGE side of the dipstick 4 Remove oil filler cap 2 If necessary add oil 5 Clean the oil filler cap and install the oil filler cap 6 Close the access cover 103 Maintenance Section Engine Oil Level Check 101400018 Engine Oil and Filter Change SMCS Code 1308 1318 510 Hot oil and components can cause personal in jury Do notallow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the 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 900737704 Illustration 187 1 Remove the plug adapter from the drain valve if equipped 2 Install a 19 05 mm 0 750 inch pipe into the drain valve The pipe requires a 3 4 14 NPTF pipe thread 3 Open the drain valve Allow the oil to drain into a suitable container A drain hose may b
36. ble solvent 111 Maintenance Section Fuel Tank Cap Filter and Strainer Replace Clean 5 Inspect the tank cap seal If the seal is damaged replace the seal 6 Replace the filter the valve the gaskets and the screws Use a 9X 2205 Cap Filter Kit 7 Install the strainer 8 Install the fuel cap Rotate the fuel cap clockwise until three tabs 5 drop into the slots in the adapter Rotate lever 3 clockwise until the lever stops Lower lever 3 over locking tab 4 100072950 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S The drain valve is under the fuel tank at the rear of the machine 1 Open the access cover if equipped g00103760 Illustration 205 2 Open the drain valve Allow the water and the sediment to drain into a suitable container 3 Close the drain valve Close the access cover if equipped 112 Maintenance Section Fuses Replace 100753704 Fuses Replace SMCS Code 1417 510 900340187 Illustration 206 The fuse panel is located in the battery compartment on the left side of the machine system from damage that is caused by overloaded electrical circuits Replace a fuse if the element separates If the fuse of a particular electrical system requires frequent replacement check the electrical circuit Repair the electrical circuit if necessary Fuses Fuses protect the electrical NOTICE Always replace fuses with the same type and
37. dary filter element 101 Maintenance Section Engine Air Filter Secondary Element Replace Illustration 182 900104397 1 Open the access cover if equipped 2 Remove the housing cover and the primary element Illustration 183 900039214 3 Remove the secondary element 4 Cover the air inlet opening Clean the inside of the air cleaner housing 5 Inspect the gasket between the air inlet and the housing If the gasket is damaged replace the gasket 6 Uncover the air inlet opening Install a new secondary element 7 Install the primary element and the air cleaner housing cover 8 Close the access cover if equipped 102 Maintenance Section Engine Air Precleaner Clean 100072811 Engine Air Precleaner Clean SMCS Code 1050 070 900103735 Illustration 184 1 Inspect the air inlet screen for dirt and for trash 2 Remove the screen Clean the screen if the screen is dirty 3 Inspect the precleaner tube for dirt and for dust 4 Clean the precleaner tube with pressure air if the precleaner tube is dirty NOTICE Service the air cleaner only with the engine stopped Engine damage could result Run the engine at high idle If the yellow piston in the filter element indicator enters the red zone service the air cleaner Stop the engine 100072815 Engine Crankcase Breather Clean SMCS Code 1317 070 Illustration 185 900103737 1 Loosen the breather outlet hose clamps
38. ding effort of this machine will be different from the brake holding effort of other machines because of the variations in the engine setting in the power train efficiency and in the brake holding ability Compare the engine speed at the beginning of machine movement to the engine speed of a prior test This will be an indication of the amount of system deterioration 1 Start the engine 2 Raise all attachments 3 Depress the brake pedal 4 Select the mode of manual shift 5 Release the parking brake 6 While the brake pedal is depressed move the directional control to the NEUTRAL position 7 Select the THIRD SPEED position The control panel will indicate 3N Note When you test the brake system make sure that the transmission is in the THIRD SPEED position You can depress the button in order to read the speed on the digital display window 8 Select the FORWARD position The control panel will indicate SF 9 Gradually increase the engine speed to full load speed The machine should not move 10 Move the directional control to the NEUTRAL position 11 Move the 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 94 Maintenance Section Cab Filter Fresh Air Clean Inspect Replace NOTICE If the machine moved while testing the brakes contact your Caterpillar dealer Have the dealer inspect and
39. ducts Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component 900677554 Illustration 199 900104007 1 Element 2 Bowl 3 Drain Bowl 2 should be monitored daily for signs of water If water is present drain the water from the bowl 1 Open drain 3 The drain is a self ventilated drain Catch the draining water in a suitable container Dispose of the water properly 2 Close drain 3 NOTICE The water separator is under suction during normal engine operation Ensure that the drain valve is tight ened securely to help prevent air from entering the fuel system i01399154 Fuel System Primary Filter Replace SMCS Code 1260 510 PY 1261 A WARNING Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes Personal injury or death can result from engine overspeed If the engine overspeeds it can cause injury or parts damage Be prepared to stop the engine by closi
40. e attached to the pipe to aid in draining 4 When the oil has completed draining from the crankcase close the drain valve Remove the pipe Install the plug adapter 104 Maintenance Section Engine Valve Lash Check 5 Remove the engine oil filter element and discard the engine oil filter element properly Make sure that all of the old filter seal is removed from the filler base 6 Apply a thin coat of oil to the new filter seals Install the new engine oil filter elements by hand When the gaskets contact the filter base tighten the filter elements by an additional turn of 270 degrees Rotation index marks are on the new filter elements These rotation index marks are spaced at 90 degree intervals Use these rotation index marks as a guide for proper tightening 900103751 Illustration 188 7 Remove the oil filler cap 1 Fill the crankcase with new oil See Operation and Maintenance Manual Refill Capacities Clean the oil filler cap and install the oil filler cap 8 Always measure the oil level with the dipstick in order to ensure that the correct amount of oil was added 9 On the dipstick maintain the oil level within the operating range i01177320 Engine Valve Lash Check SMCS Code 1102 1209 535 In order to perform the procedure for the valve lash check and for the engine valve lash adjustment refer to Systems Operation Testing and Adjusting SENR5594 Air Inlet and Exhaust System Note Ma
41. e ferrule is placed into a socket on the drum Use the following table to order the cable Table 21 Wire Cable Wire Rope Recommended Holding Capacity Diameter Ferrule 25 mm 1 inch L 8 91 m 300 ft 29 mm J 9 84 m 276 ft 1 13 inch 32 mm J 10 59 m 193 ft 1 25 inch 1 Put the cable in a straight line behind the tractor 132 Maintenance Section Window Washer Reservoir Fill Illustration 261 900550538 1 Install the ferrule end into the socket 2 Reel in the cable 57 The cable is attached to the drum on the winch with a standard cable ferrule The ferrule is placed into a socket on the drum and the ferrule is secured with a bolt on retainer Ferrules are made in several diameters and lengths Use the following table to order the cable Table 22 Wire Cable Wire Rope Recommended Holding Capacity Diameter Ferrule 25 mm 1 inch L 8 73 m 239 ft 29 mm J 9 58 m 190 ft 1 13 inch 1 Put the cable in a straight line behind the tractor 900392987 Illustration 262 1 Remove ferrule retainer 1 Install the ferrule end into socket 2 2 Install ferrule retainer 1 3 Reel in the cable 101279658 Window Washer Reservoir Fill SMCS Code 7306 544 NOTICE When operating in freezing temperatures use Caterpillar or any commercially available nonfreezing window washer solvent Illustration 263 900103795 E
42. he fuse panel is in the battery compartment on the left side of the machine 0 00 0009 Illustration 166 g00103722 Circuit Breaker Reset 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 1 Alternator 80 Amp 2 Heater and Air Blower Motor Reset 20 Amp 101399691 Cooling System Extended Life Coolant Change SMCS Code 1350 044 1395 044 For information about adding an extender to your cooling system see the Topic Cooling System Extended Life Coolant Extender Add in this manual or consult your Caterpillar dealer NOTICE Make sure you read and understand the information in the topics Safety and Cooling System Specifica tions for all information pertaining to water antifreeze and supplemental coolant additive requirements be fore you proceed with maintenance of the cooling sys tem To Drain the Cooling System The filler cap is located inside the access door in the top left side of the radiator guard 95 Maintenance Section Cooling System Extended Life Coolant Change Illustration 167 900581795 1 Slowly loosen the filler cap in order to relieve system pressure Remove the filler cap Illustration 168 900737499 2 Remove the pipe plug The pipe plug is
43. he right rear side of the machine 116 Maintenance Section Lift Cylinder Yoke Bearings Lubricate Illustration 215 900104436 1 Maintain the oil level to the FULL mark in the sight gauge 900462980 Illustration 216 2 If the hydraulic system requires additional hydraulic oil remove the filler cap and add oil through the filler tube 3 Clean the filler cap and install the filler cap 100078314 Lift Cylinder Yoke Bearings Lubricate SMCS Code 5102 086 BD Illustration 217 900104380 The fittings are on the left front side of the machine and on the right front side of the machine Lubricate the bearings by applying grease to the fittings 100060978 Oil Filter Inspect SMCS Code 1318 507 3067 507 5068 507 Inspect A Used Filter for Debris Illustration 218 900100013 The element is shown with debris Use a 4C 5084 Filter Cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can indicate a possible failure If metals are found in the filter element a magnet can be used to differentiate between ferrous metals and nonferrous metals Ferrous metals can indicate wear on steel parts and on cast iron parts Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings rod bearings or turbocharger bearings Small amounts
44. hten the filter 7 Open the fuel shutoff valve Close the access door if equipped 110 Maintenance Section Fuel System Secondary Filter Replace 8 Prime the fuel system 100073327 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE A WARNING Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes A WARNING Personal injury can result when using cleaner sol vents To help prevent personal injury follow the instruc tions and warnings on the cleaner solvent contain er before using A WARNING Personal injury or death can result from a fire Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire Clean up all leaked or spilled fuel Do not smoke while working on the fuel system Turn the disconnect switch OFF or disconnect the battery when changing fuel filters NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts g00103879 Illustration 202 Before you replace the secondary fuel filter element replace the primary fuel filter element The secondary fuel filter is behind the access door on the right side of the machine 1 Shut off
45. ine 900589924 Illustration 243 1 Remove the filter housing drain plug The filter housing drain plug is located under the fender on the right side of the machine Drain the oil into a suitable container Reinstall the filter housing drain plug Illustration 244 900463529 2 Remove the filter element cover assembly 3 Remove the filter element and properly discard the filter element 4 Clean the filter element housing with a clean cloth 5 Inspect the seal If the seal is damaged replace the seal 6 Install the new filter element Install the filter element housing cover 7 Start the engine 900602393 Illustration 245 8 Maintain the oil level to the FULL mark on the dipstick If necessary add oil through the filler tube 9 Stop the engine i01137892 Transmission Oil Level Check SMCS Code 3030 535 FLV 3080 535 FLV A WARNING Hot oil and components can cause personal in jury Do notallow hot oil or components to contact skin The transmission oil dipstick is under the access cover on the right fender of the machine 900602393 Illustration 246 1 Open the access cover Check the dipstick when the engine is running at low idle and the oil is at operating temperature Maintain the oil between the LOW mark and the FULL mark Note When you are operating the machine on severe slopes the quantity of oil in the transmission can be increased up to 10 percent When y
46. is low 98 Maintenance Section Cooling System Water Temperature Regulator Replace Illustration 174 900101147 2 If it is necessary to add coolant remove the radiator cap slowly in order to relieve the pressure 3 Fill the cooling system to the bottom of the filler tube Adding coolant above the bottom of the filler tube will cause the coolant to overflow the cooling system 4 Maintain the coolant level between the top of the sight glass and the bottom of the filler tube If you need to add coolant daily check the cooling system for leaks 5 Inspect the radiator cap and the radiator cap seal for debris for foreign material or for damage Clean the radiator cap with a clean cloth Replace the radiator cap if the radiator cap is damaged 6 Install the radiator cap 7 Inspect the radiator core for debris Clean the radiator core if necessary Use compressed air high pressure water or steam to remove dust and debris from the radiator core However the use of compressed air is preferred i01399200 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 Replace the thermostat on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system A new thermostat should be installed after the cooling system has been cleaned Install the thermostat while the cooling system is completely drained or while the cooling system coolant is drained to
47. ke sure that qualified service personnel check the injector fuel timing If an adjustment is necessary make sure that qualified service personnel adjust the injector fuel timing Special tools and training are required Note The correct fuel timing specification is shown on the Engine Information Plate Fuel timing specifications will be different with each engine application and with each power rating Consult your Caterpillar dealer for the complete adjustment procedure i00711565 Engine Valve Rotators Inspect SMCS Code 1109 040 When inspecting the valve rotators protective glasses or face shield and protective clothing must be worn to prevent being burned by hot oil or spray 1 Start the engine Run the engine at low idle Illustration 189 900038585 2 Watch the top surface of each valve rotator Whenever an inlet valve closes or an exhaust valve closes each valve rotator should turn 3 If a valve rotator fails to rotate consult your Caterpillar dealer for service Note Caterpillar recommends replacing valve rotators that are operating improperly An improperly operating valve rotator will shorten valve life because of accelerated wear on the valves Note If a damaged valve rotator is not replaced some valve face guttering could result Metal particles from the valve could fall into the cylinder This could cause damage to the piston head and to the cylinder head 100080128 Equalizer Bar Pins
48. ller tube Adding coolant above this area of the filler tube will cause the coolant to overflow the cooling system 5 Inspect the filler cap gasket Replace the filler cap if the gasket is damaged 6 Install the filler cap 97 Maintenance Section Cooling System Level Check i00072607 Cooling System Level Check SMCS Code 1353 535 FLV 1395 535 FLV At operating temperature the engine coolant is hot and under pressure Steam can cause personal injury Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand Remove the fill cap slowly to relieve pressure Cooling system conditioner contains alkali Avoid contact with the skin and eyes to prevent personal injury This machine s radiator has a surge tank There is no top tank in this cooling system The surge tank has a filler cap and a sight glass It is not necessary to remove the filler cap in order to check the coolant level The sight glass is inside the engine compartment that is on the front left side of the machine The filler cap is beneath the access door that is on the top left side of the radiator guard sere mm Y 900103926 Illustration 173 1 Observe the sight glass in order to verify the level of the coolant If the coolant completely covers the sight glass the coolant level is okay If the coolant level is visible in the sight glass the coolant
49. ly a thin coat of oil to the seals on the new filter element Hot oil and components can cause personal in jury Do not allow hot oil or components to contact 6 Install filter group 2 Tighten the new filter group skin to a torque of 60 10 N m 44 3 7 4 Ib ft 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 7 Install a new filter group 1 by hand When the filter contacts the base tighten the filter for an additional 3 4 turn 8 Remove the retainer ring from the oil filler tube NOTICE 9 Remove the strainer from the oil filler tube Care must be taken to ensure that fluids are contained during performance of inspection maintenance test 10 Wash the screen in a clean nonflammable ing adjusting and repair of the machine Be prepared solvent to collect the fluid with suitable containers before opening any compartment or disassembling any 11 Inspect the seal on the filler cap Replace the component containing fluids seal if the seal is worn or if the seal is damaged Refer to Special Publication NENG2500 Caterpillar 12 Install the strainer the retainer ring and the cap 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 The hydraulic tank is on t
50. maged replace the belts in sets Illustration 154 900103677 2 Inspect the condition of the fan and of the alternator belt The belts should deflect 9 to 15 mm 38 to 62 inch under 110 N 25 Ib of force 900103678 Illustration 155 3 Loosen the adjusting locknut 4 Turn the adjusting nut until the correct belt tension is reached To achieve the correct belt adjustment move the alternator inward or move the alternator outward as required 5 Tighten the adjusting locknut 6 If new belts are installed check the belt adjustment again after 30 minutes of engine operation 7 Close the access door 90 Maintenance Section Angle Blade Manual Tilt Brace Lubricate i01034553 Angle Blade Manual Tilt Brace Lubricate SMCS Code 6074 086 If equipped Illustration 156 900103702 Lubricate the two fittings Use Multipurpose Lithium Complex Grease with Molybdenum MPGM i01309186 Backup Alarm Test SMCS Code 7406 081 Illustration 157 900103574 Turn the engine start switch to the ON position in order to perform the test Illustration 158 900339521 Apply the service brakes Disengage parking brake switch 1 Move transmission direction selector 2 to the REVERSE position The backup alarm should sound immediately The backup alarm should continue to sound until the transmission direction selector is moved to the NEUTRAL position or to the FORWARD positi
51. mental coolant additive element at this time 8 Start the engine Run the engine without the filler cap until the thermostat opens and the coolant level stabilizes 900103926 Illustration 170 9 Observe the sight glass in order to verify the level of the coolant If the coolant completely covers the sight glass the coolant level is okay If the coolant level is low in the sight glass the coolant level is low 10 If the gasket is damaged replace the filler cap Install the filler cap 11 Stop the engine NS v N NTR SN AI Ul Ay W 2 S 4 Illustration 171 900533931 12 Clean the radiator cores with compressed air You may need to use water in order to remove debris 101380673 Cooling System Extended Life Coolant Extender Add SMCS Code 1350 1352 544 NL 1395 544 NL 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 Table 20
52. n Line Dryer Replace If Equipped SMCS Code 7322 510 A WARNING 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 under 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 The in line dryer is located behind the lower engine access door on the left side of the machine The in line dryer contains the orifice tube a desiccant that dries the liquid refrigerant and a tracer dye wafer 87 Maintenance Section Air Conditioner In Line Dryer Replace Illustration 151 900676891 1 Quick disconnect fitting for the OUTLET hose 2 Orifice tube assembly
53. ng 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 109 Maintenance Section Fuel System Primary Filter Replace Illustration 200 g00103874 1 Open the access door if equipped at the rear of the machine Turn the red handle of the fuel shutoff valve in order to shut off the fuel supply 2 Open the access cover for the engine compartment The access cover is located on the right side of the machine Illustration 201 g00103875 3 Remove the filter with a strap wrench 4 Wash the filter mounting base in clean nonflammable solvent Make sure that all of the old seal is removed 5 Coat the seal of the new filter element with clean diesel fuel 6 Install the new filter element by hand When the seal contacts the base tighten the filter element for an additional 3 4 turn Rotation index marks are positioned on the filter elements at 90 degree intervals Use these rotation index marks as a guide when you tig
54. not form e t will not be necessary to top off the system with compressor oil or refrigerant Note The R 134a refrigerant dryer should be replaced annually Extremely humid operating conditions may require more frequent replacement of the dryer The dryer should also be replaced if the air conditioning system has been leaking or if the system has been opened for service repair i01363439 Air Conditioner System Check Replace SMCS Code 7320 510 7320 535 A WARNING Personal injury can result from contact with refrig erant This system is under pressure at all times engine running or not Heat should never be applied to a charged system Contact with refrigerant can cause frost bite Keep face and hands away to help prevent injury Protective goggles must always be worn when re frigerant lines are opened even if the gauges in dicate the system is empty of refrigerant Always use caution when a fitting is removed Slowly loosen the fitting If the system is still un der pressure release it slowly in a well ventilated area Personal injury or death can result from inhaling refrigerant through a lit cigarette Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Do not smoke when servicing air conditioners or wherever refrigerant gas may be present Befo
55. nt or while you clean the air cleaner housing 900104396 Illustration 177 1 Open the access door if equipped 100 Maintenance Section Engine Air Filter Primary Element Clean Replace Illustration 178 900103726 2 Remove the air cleaner cover Illustration 179 900100510 3 Remove the primary filter element from the air cleaner housing 4 Mark the primary 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 Reference Refer to Operation and Maintenance Manual Engine Air Filter Secondary Element Replace 5 If the primary filter element has been cleaned six times replace the primary filter element Also replace the primary element if the primary element has been used for one year Proceed to Step 9 Illustration 180 900039201 6 Clean the inside of the air cleaner housing 7 If the primary filter element has not been cleaned six times inspect the primary 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 NOTICE Do not clean the filter elements by
56. 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 100078842 Pivot Shaft Oil Level Check SMCS Code 4153 535 FLV A WARNING Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Illustration 219 g00104456 The sight gauge for the oil reservoir is on the left side of the machine Maintain the oil within the limits of the sight gauge 117 Maintenance Section Pivot Shaft Oil Level Check Illustration 220 900104448 In order to fill the oil reservoir open the access door on the left side of the machine Remove the oil filler cap in order to add the oil to the oil reservoir 100058126 Radiator Core Clean SMCS Code 1353 070 1805 1810 Illustration 221 900100624 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
57. oil level in the other final drive i01256760 Front Idler Position Check SMCS Code 4159 Illustration 196 900669323 A Adjusting shims B Dimension between the height of the front idler tread and the height of the roller tread 107 Maintenance Section Front Idler Position Check The height of the front idler tread should always be higher than the height of the roller tread The dimension B is set approximately to 9 0 mm 35 inch at the factory Dimension B decreases as the undercarriage wears If a rebuilt idler or a new idler is installed with track rollers that are worn dimension B decreases Adjustment of the front idler to the correct height can improve the ride of the tractor and the performance of the dozer Use the following procedures to determine the best operating position If the machine is operated on FIRM UNDERFOOT conditions and excess vibration occurs shims can be removed in order to raise the front idler If the machine is operated on SOFT UNDERFOOT conditions and dozing performance is poor shims can be installed in order to lower the front idler Lowering the front idler can improve dozing performance If ground rippling by the dozer or excess vibration occur in soft material shims can be removed in order to raise the front idler Consult your Caterpillar dealer for detailed information about checking the idler and about adjustments to the idler 100072933 Fuel System Prime
58. on 900637537 Illustration 159 The toggle switch is located under the protective cap The backup alarm is on the rear right side of the machine To adjust the sound level move the toggle switch that is on the rear of the backup alarm The backup alarm is set at the highest sound level when the machine is shipped from the factory The adjustment knob should remain at the HIGH position unless the job site requires a lower sound level 100998344 Battery Inspect SMCS Code 1401 040 Tighten the battery retainers on all batteries at every 1000 hour interval Perform the following procedures at every 1000 hour interval Check the following areas more often as required e Clean the top of the batteries with a clean cloth e Keep the terminals clean and coat the terminals with petroleum jelly Keep the terminal covers in place 1 Open the battery access cover 2 Clean the top of the batteries with a clean cloth Keep the terminals clean and coated with petroleum jelly Install the terminal covers after you coat the terminals 3 Close the battery access cover i01324649 Battery Electrolyte Level Check SMCS Code 1401 535 FLV Maintenance free batteries are installed at the factory Table 19 MAINTENANCE INTERVALS FOR BATTERIES Battery Interval Conventional 100 Hours Low Maintenance 250 Hours Maintenance Free Maintenance Free Each battery cell should not require more
59. or If the tip is too blunt the tip will not penetrate properly 1 Raise the ripper Place blocking under the ripper Lower the ripper onto the blocking The ripper should be high enough so that the ripper tip or the shank protector can be removed Do not place the ripper too high 2 If the ripper tip is worn drive out the pin Remove the tip and the shank pin retainer 3 Clean the shank pin retainer and the pin 4 Install the new tip and the retainer 5 Install the pin from the opposite side of the retainer 6 If the shank protector is worn drive out the pins Remove the shank protector 7 Clean the pin retainers and the pins 8 Install the new shank protector and the retainers 9 Install the pins from the opposite side of the retainer 10 Raise the ripper and remove the blocking 11 Lower the ripper to the ground 119 Maintenance Section Rollover Protective Structure ROPS Inspect i01178020 Rollover Protective Structure ROPS Inspect SMCS Code 7325 040 Illustration 226 000104495 Inspect the Rollover Protective Structure ROPS for bolts that are loose or damaged Replace any damaged bolts and any missing bolts with original replacement parts only Tighten the bolts to a torque of 900 100 N m 663 8 73 8 Ib ft Note Apply oil to all bolt threads for the ROPS before you install the bolts Improper bolt torque can result if you do not apply oil to the threads Do not weld
60. ou are operating with the increased oil quantity prolonged operation in some machines can cause high transmission oil temperatures After the work on the severe slopes has been completed drain the excessive oil quantity from the bevel gear case 2 Remove the filler cap for the power train If necessary add oil 3 Clean the filler cap and install the filler cap Replace the filter element if the transmission oil filter indicator comes on during operation See Operation and Maintenance Manual Transmission Oil Filter Replace 4 Close the access cover 127 Maintenance Section Transmission Oil Level Check 100073242 Transmission Scavenge Screen Clean SMCS Code 3030 070 MGS When you change the transmission oil clean the scavenge screen 900104061 Illustration 247 1 Remove the cover from the rear of the transmission The scavenge screen is located behind the cover 2 Wash the screen in a clean nonflammable solvent 3 Inspect the seal If the seal is damaged replace the seal 4 Install the screen and the cover 100078430 Walk Around Inspection SMCS Code 7000 040 NOTICE Accumulated grease and oil on a machine is a fire hazard Remove debris with steam cleaning or high pressure water at the specified interval in the Maintenance In terval Schedule or each time any significant quantity of oil is spilled on the machine Note Watch closely for leaks If leaking is observed find
61. pressure Grease coming out of the relief valve under pres sure can penetrate the body causing injury or death Do not watch the relief valve to see if grease is es caping Watch the track or track adjustment cylin der to see if the track is being loosened Loosen the relief valve only one turn Move the machine forward Allow the machine to stop without the use of the service brakes Adjust the tracks while you are in the machine s typical operating conditions If packing conditions prevail on the workplace the tracks should be adjusted with packing material Illustration 229 900040329 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 2 is 115 10 mm 4 5 0 4 inch for machines with the STD undercarriage The correct adjustment of dimension 2 is 127 10 mm 5 0 0 4 inch for D7R machines with the LGP undercarriage 0 Illustration 230 900104000 If the machine is equipped with a carrier roller the sum of the correct adjustment of dimension 3 and dimension 4 is 130 10 mm 5 1 0 4 inch 121 Maintenance Section Track Adjustment Adjust Loose Track Adjustment Illustration 231 900040335 NOTICE Do not attempt to tighten track when dimension 1 is 138 mm 5 4 inch or more Contact your Caterpillar dealer for track service or in structions 1 Remove the access cover 9
62. re any checks of the air conditioning and heating system are made move the machine to a smooth horizontal surface Lower all implements to the ground Make sure the transmission is in neutral or park and that the parking brake is engaged Keep all other personnel either away from the machine or where they can be seen Before you do a performance check of the air conditioning system check the following items 1 Check the condenser a Check for any type of restriction that will obstruct the air flow Check for dirt insects plastic bags etc b With condensers that are mounted on the roof always check that both the fan motors are running Check for restrictions A clean condenser will lead to longer life for the compressor 000737294 Illustration 152 2 Clean the fresh air filters m Ja 900737301 Illustration 153 3 Clean the recirculation filters 4 Replace the in line dryer annually Reference Refer to the topics of Service Manual SENR5664 Receiver Refrigerant Dryer Remove and Install and of Service Manual SENR5664 In Line Refrigerant Dryer Remove and Install in the Service Manual for your machine 100072461 Alternator and Fan Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 1 Open the access door on the right side of the machine 89 Maintenance Section Alternator and Fan Belts Inspect Adjust Replace Note Even if only one belt is worn or da
63. ry Always return used batteries to one of the following locations e A battery supplier e An authorized battery collection facility e Recycling facility 100091365 Brakes Indicators and Gauges Test SMCS Code 4100 081 7000 081 7450 081 Illustration 161 900104090 Check the operation of the Caterpillar Monitoring System Observe the self test when you start the engine The system performs an automatic self test when you turn the engine start switch to the ON position The self test verifies that the monitoring panel and the display modules are operating properly The internal circuits the indicators and the gauges are automatically checked Illustration 162 900104091 The operator must observe the indicators and the gauges in order to determine whether module 1 module 2 module 3 the indicators and the gauges are operating properly The self test lasts for approximately three seconds During the self test all alert indicators flash The digital display shows the following readouts e All indicators of units Deg C kPa rpm and liters e X10 readout e Symbol for the hour meter e 8 8 8 X 8 8 readout The pointers in the gauges point upward Then the pointers point to the left Then the pointers point to the right Then the pointers point to the final positions e The gear direction readout shows e The speed re
64. sary repairs m TA m mo ed T Illustration 249 900104415 e Inspect the hydraulic system for leaks Repair any hydraulic system leaks Inspect the hoses the seals and the flanges e Inspect the final drive for leaks Repair any final drive leaks n ya Illustration 250 900104416 e Make sure that the covers and the guards are secured Inspect the covers and the guards for damage for loose bolts and for missing bolts Replace missing bolts Tighten the replaced bolts to the proper torque e Inspect the transmission for leaks Repair any transmission leaks Check around the seals and around the covers Also check the hoses around the transmission Illustration 251 900104417 e Inspect the tracks Repair the tracks if the tracks are damaged or excessively worn Tighten any loose bolts Replace missing bolts Check the tracks for excessive dirt buildup Check the tightness of the track Refer to Operation and Maintenance Manual Tracks Adjustment Check e Inspect the guiding guards for the track Check for loose bolts or for missing bolts Check the track components for damage and for wear Replace missing bolts e Inspect the operator compartment for cleanliness Remove any trash buildup and any dirt buildup e Inspect the instrument panel Repair any broken gauges and any broken lights g00104418 Illustration 252 e Make sure that the horn the backup alarm
65. the lights the guards and the shield are working properly 129 Maintenance Section Winch Filter and Magnetic Strainer Replace Clean Winch Filter and Magnetic Strainer Replace Clean SMCS Code 5163 070 Fl MGS 5163 510 Fl MGS Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Illustration 253 900040007 1 Remove the cover and the gasket Illustration 254 900040006 2 Remove the filter element housing with a wrench 3 Remove the filter element from the filter element housing 4 Clean the filter element housing with a clean cloth 5 If the seal is damaged replace the seal Lubricate the seals with clean oil 130 Maintenance Section Winch Oil Change 6 Install a new filter element into the filter element housing 7 Tighten the filter element housing to a torque of27 x 4 20 3 Ib ft 8 Install the cover and the gasket Clean the Magnet and Clean the Strainer 900040008 Illustration 255 1 Remove the cover the magnet and the strainer 2 Clean these parts in a clean nonflammable solvent 3 Install the strainer and the magnet 4 Install the cover Winch Oil Change SMCS Code 5163 044 Hot oil and components can cause personal in jury Do notallow hot oil or components to contact skin Illustration 256 1 Illustration 257 2 900039947 Remove the oil filler plug 900039945
66. the fuel supply The fuel shutoff valve is under the fuel tank on the rear of the machine 2 Remove the filter element Discard the filter element properly 3 Clean the filter housing base Make sure that all of the old seal is removed 4 Coat the seal of the new filter element with clean diesel fuel 5 Install the new filter element by hand When the seal contacts the base tighten the filter element for an additional 3 4 turn Rotation index marks are positioned on the filter element at 90 degree intervals Use these rotation index marks as a guide when you tighten the filter 6 Open the fuel shutoff valve 7 Prime the fuel system i01256353 Fuel Tank Cap Filter and Strainer Replace Clean SMCS Code 1273 070 STR 1273 070 Z2 Illustration 203 900669021 The fuel is located on the rear of the machine The cap is on the left side of the machine Only vented fuel caps have filters Machines without the fast fill fuel arrangement require a vented fuel cap Illustration 204 900668917 1 Lift lever 3 in order to remove the fuel tank filler cap Turn the lever counterclockwise until the lever stops Lift the cap straight up in order to remove the cap 2 In order to remove the filter remove two screws that secure filter 2 to the fuel cap Remove filter 2 valve 1 and the gaskets 3 Remove the fuel strainer from the filler neck 4 Wash the cap and the strainer in a clean nonflamma
67. the source of the leak and correct the leak If leaking is suspected or leaking is observed check the fluid levels more frequently 128 Maintenance Section Walk Around Inspection 900104413 Illustration 248 e Inspect all of the implements for damage or for excessive wear Repair the implements if the implements are damaged Inspect the attachment cylinders and the attachment linkage for damage or for excessive wear Repair any damages Inspect the lights for broken bulbs and for broken lenses Replace any broken bulbs and any broken lenses Remove any trash buildup around the engine Remove any trash buildup that is under the floorplate Also remove any dirt buildup that is on the top of the crankcase guard Inspect the cooling system for leaks and repair any cooling system leaks Check the hoses the radiator fins the radiator cap and the drain area Inspect the engine precleaner screen for any dirt buildup and for debris buildup Remove any dirt and debris Inspect the engine compartment for leaks and repair any engine compartment leaks Check around all seals and around all covers Inspect the condition of the steps and of the handholds Inspect the steps and the handholds for cleanliness If necessary repair the steps or clean the steps Inspect the Rollover Protective Structure ROPS for damage Inspect the Falling Object Protective Structure FOPS for damage Consult your Caterpillar dealer for any neces
68. tick 10 Unscrew the transmission breather and remove the transmission breather The transmission breather is located on the top of the bevel gear case Remove the floorplate in order to access the transmission breather 11 Wash the transmission breather in a clean nonflammable solvent 12 Install the transmission breather i01097929 Transmission Oil Filter Replace SMCS Code 3067 510 A WARNING Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin 126 Maintenance Section Transmission Oil Filter Replace NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before 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 Initially replace the transmission oil filter after 250 service hours Also replace the transmission oil filter after the initial 500 service hour interval Thereafter replace the transmission oil filter after every 500 service hours The transmission oil filter is located behind the access cover on the right side of the mach

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