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MAINTENANCE INTERVALS - Safety

1. Was Wes Was Y g N 3 l Mi joe Ve it i igs ma Illustration 221 g01053343 1 Open the access door on the left side of the machine 1 Illustration 222 g01053304 2 Loosen the cylinder retaining clamp 2 Unscrew the empty ether starting aid cylinder 3 and remove the cylinder 3 Remove the used gasket Install the new gasket that is provided with each new cylinder 4 Install the new cylinder Tighten the cylinder by hand Tighten the cylinder retaining clamp securely 5 Close the engine access door 156 Maintenance Section Final Drive Oil Change SEBU7764 10 101834830 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 com ponent c
2. Illustration 247 901944044 Top view of the Hydraulic Tank FR A A Illustration 248 oar Return screens A Implement return B Case drain return C Fan return 9 Remove return screens that are within reach It may be necessary to remove the filter from the top to reach one return screen Clean the screens with a clean nonflammable solvent 10 Inspect the O ring seal if the casting is removed If the seal is damaged replace the seal 11 Replace the return screens 12 Replace hydraulic tank access cover 7 13 Assemble the drain lines 14 Fill the hydraulic tank Reference For the correct procedure refer to Operation and Maintenance Manual Hydraulic System Oil Change 15 Replace filler cap 1 SEBU7764 10 173 Maintenance Section Hydraulic System Oil Change 102187439 Hydraulic System Oil Change SMCS Code 5050 044 Note The normal hydraulic oil change interval is at every 2000 Service Hours or 1 Year By performing S O S oil analysis the hydraulic oil change interval may be extended to 4000 Service Hours or 2 Years S O S oil analysis must be performed at every 500 Service Hours or 3 Months in order to extend the hydraulic oil change interval The results from the S O S oil analysis will determine if the hydraulic oil change interval may be extended If S O
3. 102039230 Ripper Linkage and Cylinder Bearings Lubricate SMCS Code 6313 086 BD L4 Note There are a total of twelve grease fittings for the ripper linkage and hydraulic cylinder bearings Illustration 284 g01048827 Lubricate the grease fittings for the hydraulic cylinder bearings 1 2 3 and 4 Illustration 285 g01048866 Lubricate the remote grease fittings for the pins 5 190 Maintenance Section Ripper Tip and Shank Protector Inspect Replace SEBU7764 10 Illustration 286 g01048879 Lubricate the grease fittings for the pins 6 Ripper Tip and Shank Protector Inspect Replace If Equipped SMCS Code 6808 040 6808 510 6810 6812 040 6812 510 ee Illustration 287 g00945595 1 Ripper tip 2 Shank protector When the ripper tip is worn close to the shank replace the ripper tip When the shank protector is worn close to the shank replace the shank protector If the tip is too blunt the tip will not penetrate properly 1 Raise the ripper Place blocking under the ripper Lower the ripper onto the blocking The ripper should be high enough so that the ripper tip or the shank protector can be removed Do not place the ripper too high 2 If the ripper tip is worn drive out the pin Remove the tip and the shank pin retainer 3 Clean the shank pin retainer and the pin 4 Install the new tip and the retainer 5 Install
4. 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 installing the low pressure fuel lines Hydraulic System Filter Bypass Screen Clean SMCS Code 5068 070 The screen should be cleaned especially when one of the following situations have occurred e Failure of the Implement Pump e Failure of the Fan Pump e Failure of the Fan Motor Cleaning of the Hydraulic Tank e PCR Engine Overhaul 1 Park the machine on a level surface Lower the work tool to the ground Engage the parking brake 2 Turn the engine start switch key to ON 3 Move the hydraulic control levers through all of the positions in o
5. Form PEHP7076 Understanding the S 0 S Oil Analysis Tests Procedure for Changing the Engine Oil and Filter Illustration 206 g01051084 1 Open the engine access door on the left side of the machine Illustration 207 g01047383 2 If the machine is equipped with a high speed oil change arrangement use a nozzle assembly in order to drain the oil from the crankcase l p oo Illustration 208 g01051220 3 The access cover for the crankcase drain is located in the belly guard underneath the front of the machine Remove the bolt in order to remove the access cover SEBU7764 10 151 Maintenance Section Engine Oil and Filter Change Illustration 209 g01047321 4 Open the crankcase drain valve Allow the oil to drain into a suitable container A drain hose may be attached to the crankcase drain valve in order to aid the draining of the oil 5 When the oil has been completely drained from the crankcase close the crankcase drain valve Close the crankcase drain access cover Ser al Sis A REA WC Illustration 210 g01222997 6 Remove the crankcase oil filter elements 5 and discard the crankcase oil filter elements properly Make sure that all of the old filter seals are removed from the filter base 7 Apply a thin film of clean engine oil to the sealing surface of the new filter element 8 Instal
6. 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 21 Note Do not use API CF 4 oils in Caterpillar machine diesel engines Abnormally harsh operating cycles or harsh environments can shorten the service life of the engine oil Arctic temperatures corrosive environments or extremely dusty conditions may require a reduction in engine oil change intervals from the recommendations in Table 21 Also refer to Manual SEBU5898 Cold Weather Recommendations for all Caterpillar Machines Poor maintenance of air filters or of fuel filters requires reduced oil change intervals See your Cat dealer for more information if this product will experience abnormally harsh operating cycles or harsh environments Table 21 D10T Series Engine Oil Change Interval Operating Conditions Severe Multigrade High Sultur above Oil Type Normale Load above 1830 m Factor 0 3 6000 4 ft Cat DEO soo hr 500 hr 250hr 250 hr Preferred ECF 2 pSr 500hr S500 hr 250hr 250 hr 150 ECF 1 a 250hr 250 hr 159 250 hro 1 The traditional oil change interval for engines is 250 hours The standard oil change interval in this machine is 500 hours if the operating conditions and recommended oil types that are listed in this table are met
7. 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 Place the sample in the shipping sleeve 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 _ Park the machine on a hard level surface Set the engine at low idle speed Illustration 184 RJG1 528 Illustration 185 g01218874 RJG529 Up Right side view 2 The sampling valve for the coolant is located on the right side of the engine 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 102050545 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 sch
8. 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 SEBU7764 10 133 Maintenance Section Cooler Cores and A C Condenser Clean For more information on WAVS refer to Operation and Maintenance Manual SEBU8157 Work Area Vision System 102784223 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 the air conditioning system Aftercooler RJG1 528 Note The remote air to air aftercooler core RATAAC that is used on machines RJG1 528 uses a hydraulic fan that is mounted to the bottom of the hood Illustration 170 g01106873 Left side view of aftercooler RJG1 528 1 Hood 2 Precleaner Aftercooler 4 Manifold 5 Air duct Accessing the Remote Aftercooler Core 1 Remove the manifold 2 Remove the bolts along the manifold 3 Unfasten the clamps that attach the air ducts 4 Lift t
9. 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 tooling NOTICE The machine must be parked on a level surface to perform this procedure 146 Maintenance Section Engine Mounts and Equalizer Bar Inspect SEBU7764 10 Personal injury or death can occur from not fol lowing the proper procedure or the recommended tooling To prevent the possibility of injury or death follow the established procedure using the recommend ed tooling NOTICE The machine must be parked on a level surface to perform this procedure Note All the weight of the machine must be removed from the equalizer bar Equalizer bar must have free movement in order to be measured To check the equalizer bar center pin for looseness and for unusual wear perform the following steps 6 Illustration 197 g01108801 1 Clean the areas that are around the center p
10. 025 7254 025 Adjust the Access Ladder Do not ride on ladder or stand on platform while machine is moving 178 Maintenance Section Ladder Hinge Oil Change SEBU7764 10 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 b There must be a gap between the magnet and the switch in order to prevent contact 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 Remo
11. 5 Washer 6 Retainer 1 Remove bolts 4 and washers 5 Remove retainers 6 SEBU7764 10 159 Maintenance Section Final Drive Seal Guard Packing Replace LIZ AAN K QF WE fail Ww Illustration 228 g01387828 Cross section view of seal guard 3 Seal guard 6 Retainer 7 Inner packing 9 Outer packing D 2 mm 0 079 inch 2 Inspect the packing and the seal guard for evidence of leaking through the packing Remove packing 7 and 9 from seal guard 3 Oil leakage through the packing would indicate leakage of the Duo Cone Seal Gp in the final drive Inspect the Final Drive for oil leakage through the Duo Cone Seal Gp If oil is leaking through the seal replace the Duo Cone Seal Gp Refer to the Service Manual Table 22 Required Parts PartNumber Qty Description 189 6244 2 Seal packing 129 1928 1 Grease Note Each final drive seal guard requires two 189 6244 Seals packing The sections of packing are installed on top of each other in the groove of the seal guard Illustration 229 g00941695 7 Inner packing 8 Joint in the inner packing A Diameter A 3 Install inner packing 7 Place a thin film of 129 1928 Grease on diameter A Stretch the packing during installation Smooth the packing and keep the packing uniform Minimize the joint 8 at the ends of the inner packing 7 160 Main
12. Direct the air from the clean side to the dirty side In order to show that the filter element has been cleaned mark the element The primary filter element can be cleaned up to six times NOTICE Do not clean the filter elements by bumping or tapping them Do not use filter elements with damaged pleats gaskets or seals Do not wash the filter elements 9 Push the filter element firmly in order to properly seat the element Write the date on the element if the primary element is replaced 10 Install the air cleaner cover 11 Close the access door if equipped Secondary Filter NOTICE Always replace the secondary filter element Never attempt to reuse it by cleaning The secondary filter element should be replaced at the time the primary element is serviced for the third time The secondary filter element should also be replaced if the yellow piston in the filter element indicator en ters the red zone after installation of a clean primary element or if the exhaust smoke is still black NOTICE The filter should be kept in service for no longer than one year NOTICE Always leave the secondary filter element in place while you clean the air cleaner housing 1 Open the engine access door if equipped 2 Remove the air cleaner housing cover 3 Remove the primary filter element Refer to the section Primary Filter 4 Clean the inside of the air cleaner housing Illustration 190 g004702
13. Improvements in the engine allow this engine oil change interval This new standard interval is not permitted for other machines Refer to the applicable Operation and Maintenance Manuals for the other machines 2 Normal conditions include these factors Fuel sulfur below 0 3 altitude below 1830 m 6000 ft and good air filter and fuel filter maintenance Normal conditions do not include high load factor harsh operating cycles or harsh environments 3 Load factors are defined as a function of fuel consumption rate High load factors can shorten the service life of your engine oil Continuous heavy load cycles and very little idle time result in increased fuel consumption and oil contamination These factors deplete the oil additives more rapidly If the average fuel consumption of your D10T exceeds 76 L 20 1 US gal per hour follow the High Load Factor recommendations in Table 21 To determine average fuel consumption measure average fuel consumption for a period of 50 to 100 hours If the application of the machine is changed the average fuel consumption may change 4 For sulfur content above 0 1 refer to this topic in the Manual SEBU6250 5 In order to verify an oil change interval of 500 hours refer to Program A below 6 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 A
14. Verification for an Oil Change Interval of 500 Hours 150 Maintenance Section Engine Oil and Filter Change SEBU7764 10 This program consists of three oil change intervals of 500 hours Oil sampling and analysis is done at 250 hours and 500 hours for each of the three intervals for a total of six oil samples The analysis includes oil viscosity and infrared IR analysis of the oil If all of the results are satisfactory the 500 hour oil change interval is acceptable for the machine in that application Repeat Program A if you change the application of the machine If a sample does not pass the oil analysis take one of these actions e Shorten the oil change interval to 250 hours e Proceed to Program B e Change to a preferred oil type in Table 21 Program B Optimizing Oil Change Intervals Begin with a 250 hour oil change interval The oil change intervals are adjusted by increments Each interval is adjusted an additional 50 hours Periodic oil sampling and analysis is done during each interval The analysis includes oil viscosity and infrared IR analysis of the oil Repeat Program B if you change the application of the machine If an oil sample does not pass the analysis shorten the oil change interval or change to a preferred multigrade oil type in the listing above References Reference Form PEDP7035 Optimizing Oil Change Intervals Reference Form PEDP7036 S O S Fluid Analysis Reference
15. 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 241 g01390659 Rear view The drain valve is under the fuel tank at the rear of the machine 1 Open drain valve 1 under the left side of fuel tank 2 Unlock the drain valve as needed Allow the water and the sediment to drain into a suitable container 2 Close the drain valve Lock the drain valve if necessary 102606340 Fuses and Circuit Breakers Replace Reset SMCS Code 1417 510 1420 Fuses Fuses protect the electrical system from damage that is caused by overloaded electrical circuits Replace a fuse if the element separates If the fuse of a particular electrical system requires frequent replacement check the electrical circuit Repair the electrical circuit if necessary g01053625 Illustration 242 168 Maintenance Section High Intensity Discharge Lamp HID Replace SEBU7764 10 The access cover for the fuses and the circuit breaker
16. 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 lt i 7 SECTION A A g01066628 Illustration 193 Marks of the damper are on the hub and on the ring These marks will indicate the condition of the vibration damper If the marks are not in alignment the rubber seal between the ring and the hub has separated from the ring and or from the hub Install a new damper if the marks are not in alignment Note 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 102195435 Engine Mounts and Equalizer Bar Inspect SMCS Code 1152 040 7206 040 Engine Mounts Caterpillar recommends checking the engine mounts for deterioration This will prevent excessive engine vibration that is caused from improper mounting Equalizer Bar End Pins Personal injury or death can occur from not fol lowing the proper procedure or the recommended tooling To prevent the possibility of injury or death fo
17. 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 184 Maintenance Section Power Train System Oil Sample Obtain SEBU7764 10 103652868 Power Train System Oil Sample Obtain SMCS Code 3080 008 Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates The transmission oil filter is under the fuel tank on the rear of the machine 1 If the machine is equipped with a transmission guard support the transmission guard with the proper lifting device Illustration 272 g00610800 Transmission guard at the rear of the machine N Remove the lock pin bolt secondary bar pin and washer 1 from the bracket oO Lift transmission guard 3 fr
18. clean cloth Replace the radiator cap if the radiator cap is damaged 3 Install the radiator cap i02055619 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 280 g01054329 1 Remove all of the debris around the cover plate 1 on the top of the track roller frame 188 Maintenance Section Refrigerant Dryer Replace SEBU7764 10 2 Remove the cover plate for the oil filler The dipstick 2 is part of the cover plate Illustration 281 g01054336 3 Maintain the oil level above the MIN mark on the dipstick 4 Install the cover plate 5 Repeat the procedure for the other recoil compartment 103642341 Refrigerant Dryer Replace If Equipped SMCS Code 7322 510 7322 535 Personal injury can result from contact with refrig erant Contact with refrigerant can cause frost bite Keep face and hands away to help prevent injury Protective goggles must always be worn when re frigerant lines are opened even if the gauges in dicate the system is empty of refrigerant Always use precaution when a fitting is removed Slowly loosen the fitting If the system is still un der pressure release it slowly in a well ventilated area Personal injury or death can result from inhaling refrigerant through a lit cigarette Inhali
19. completely 7 Remove the probe from the sampling valve Put the cap securely on the sampling bottle Place the sampling bottle with the completed label into the mailing tube 8 Replace the protective cap on the sampling valve 9 Close the access cover if equipped SEBU7764 10 149 Maintenance Section Engine Oil and Filter Change 103968510 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 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 NOTICE This machine is equipped with an engine that meets EPA Tier 3 Euro Stage lll or MOC Step 3 emission regulations A 500 hour engine oil change interval is available provided that operating conditions and rec ommended multigrade oil types are met When these requirements are not met shorten the oil change interval to 250 hours or use an S O S oil sampling and analysis program to determine an acceptable oil change interval
20. effects of the operating environment g01389572 Illustration 177 Turn off the engine Open both of engine access doors 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 Inspect the hydraulic lines to the RATAAC for chafing and rubbing of the hoses Replace the hydraulic lines if necessary SEBU7764 10 135 Maintenance Section Cooling System Coolant ELC Change 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 mor
21. 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 g01048998 Illustration 302 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 dealer s Custom Track Service expert can perform track inspection 102039992 Track Roller Frame Inspect SMCS Code 4151 040 Illustration 303 g01049034 Inspect the track roller frame 3 for leaks Check the seal for the pivot shaft 2 for oil leaks Check the idlers 1 and track rollers 4 for leaks Inspect the seal for the recoil spring 5 for oil leaks 102040024 Track Roller Frame Gu
22. the center of the valve 1 2 Remove the hydraulic tank filler cap 2 slowly in order to prevent the rapid escape of oil or air 3 Clean the filler strainer and the filler cap in a clean nonflammable solvent 4 Remove the oil drain plug 4 5 Attach a hose to a swivel Install the swivel and the hose into the drain plug opening A pipe nipple and a hose can also be used Do not tighten the pipe 6 Use a 8 mm wrench or a adjustable wrench to open the drain valve Allow the oil to drain into a suitable container Note If there is a failure the hydraulic tank and the hydraulic screen must be cleaned Refer to Operation and Maintenance Manual Hydraulic System Return Screen Clean for the procedure 7 Remove the swivel The valve for the hydraulic tank will close 8 Clean the drain plug and install the drain plug Tighten the drain plug to a torque of 68 7 Nm 50 5 lb ft Install the oil drain plug cover 9 Change the hydraulic system filter See Operation and Maintenance Manual Hydraulic System Oil Filter Replace 10 Install the filler strainer 11 Fill the hydraulic oil tank 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 12 Inspect the filler cap gasket Replace the gasket if damage or wear is evident 174 Maintenance Section Hydraulic System Oil Filter Pilot Replace
23. 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 SEBU7764 10 153 Maintenance Section Equalizer Bar Center Pin Measure 102092065 Equalizer Bar Center Pin Measure SMCS Code 7206 082 Illustration 214 g01066674 Rear view To check the equalizer bar center pin for looseness and for unusual wear perform the following steps Note All the weight of the machine must be removed from the equalizer bar Equalizer bar must have free movement in order to be measured 1 Clean the areas that are around the center pin with a high pressure wash g00736127 Illustration 215 Front view 2 Install a dial indicator and measure the vertical play in the center pin joint Note Schedule the center pin joint for repair if movement exceeds 2 54 mm 100 inch Consult your Caterpillar dealer for an inspection and for repair instructions 102827491 Equalizer Bar End Pins Oil Level Check Waste Handling Arrangement SMCS Code 7206 535 FLV Note If your ma
24. 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 Illustration 308 g00781090 Track Roller Frame Guide 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 102775471 Winch Fairlead Rollers Lubricate SMCS Code 5163 086 If equipped SEBU7764 10 197 Maintenance Section Winch Oil Level Check Illustration 309 g01387081 Lubricate the five fittings Use MPGM Grease 102775441 Winch Oil Level Check SMCS Code 5163 535 FLV If equipped PA140VS Illustration 310 g01387065 1 Remove the oil level plug 2 in order to check the oil level The oil level should be maintained to the bottom of the level plug hole 2 If necessary remove oil filler plug 1 and add oil Check for oil
25. workplace the tracks should be adjusted with packing material 2 To measure the sag in the track stretch a string over the grousers that are between the sprocket and the front idler Take the measurement from the string to the top of the grouser at the maximum measurement Dimension 2 is the maximum distance between the string and the grouser SEBU7764 10 193 Maintenance Section Track Check Adjust Illustration 293 g00512026 Track adjustment without carrier rollers 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 155 10 mm 6 1 40 inch Illustration 294 g00511982 Track adjustment with carrier rollers If the machine is equipped with a carrier roller the correct adjustment of dimension 3 and dimension 4 is 75 10 mm 3 0 40 inch Note The sum of dimension 3 and dimension 4 must be 155 10 mm 6 1 0 40 inch Loose Track Adjustment Illustration 295 g00945693 Location of dimension 1 Illustration 296 g00945710 Dimension 1 NOTICE Do not attempt to tighten track when dimension 1 is 193 mm 7 6 inch or more Contact your Caterpillar dealer for track service or in structions ree Illustration 297 g00945717 1 Remove access cover 5 194 Maintenance Section T
26. 01047225 RJG1 528 The secondary fuel filter is located behind the access door on the left side of the machine 166 Maintenance Section Fuel Tank Cap Filter and Strainer Replace Clean SEBU7764 10 Illustration 237 g01218164 RJG529 Up The secondary fuel filter is located behind the access door on the right side of the machine Illustration 238 g01046499 Primary fuel filter and fuel shutoff valve 1 Close the fuel shutoff valve The fuel shutoff valve is located on the front left side of the fuel tank 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 secondary filter element for an additional 1 3 to 1 2 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 101969542 Fuel Tank Cap Filter and Strainer Replace Clean SMCS Code 1273 070 STR 1273 070 Z2 NAB 2 mia TULA 3 g01022482 Illustration 239 The fuel tank is located on the rear of the machine The filler cap 1 is on the left side of the machine next to the ROPS Only vented fuel caps have filters Machines w
27. 3423 Cab Filter Fresh Air Clean Inspect Replace SMCS Code 7342 040 7342 070 7342 510 Note Clean the filters more often in dusty conditions w l Lnn Illustration 165 1 Open the access cover to the filter element The filter cover is on the left side of the machine above the battery 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 RJG1840 Up Illustration 166 g01768834 1 Loosen three clamps 2 and remove filter cover 1 The filter cover is located outside the left side of the cab 132 Maintenance Section Cab Filter Recirculation Clean Inspect Replace SEBU7764 10 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 102041123 Cab Filter Recirculation Clean Ins
28. 40 5 Remove the secondary filter element Pull out in order to remove the element SEBU7764 10 143 Maintenance Section Engine Air Precleaner Clean 6 Install a new secondary filter element Push the element firmly in order to properly seat the element Write the date on the element if the element is replaced 7 Install the primary filter element and the air cleaner housing cover 8 Close the engine access door if equipped 102053630 Engine Air Precleaner Clean SMCS Code 1050 070 1055 070 Pa fom Illustration 191 g01053125 Inspect the air inlet screen for dirt and for trash 1 Remove the screen Clean the screen if the screen is dirty 2 Inspect the precleaner tube for dirt and for dust 3 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 engine air filter indicator still flashes service the air filter Stop the engine 102781929 Engine Crankcase Breather Clean SMCS Code 1317 070 The crankcase breathers are located on the top of the engine Illustration 192 g01389603 Top view 1 Remove hose 1 from the outlet of the breather 2 on each side of the engine Note Perform steps 2 through 8 on each crankcase breather 2 Remove bolts 3 at the base of the b
29. 64 Power Train System Oil Level Check SMCS Code 3030 535 FLV Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Illustration 270 g01050163 Open the access door on the left side of the machine OIL AT OPERATING TEMP Y H OPR ZONE 18L We ENGINE STOPPED COLD OILYY eeOPR ZONE 18L Illustration 271 g00594099 HOT TRANSMISSION 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 is the only accurate way to check the oil level Remove filler plug 2 If necessary add oil Clean the filler plug and install the filler plug COLD TRANSMISSION 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 Remove filler plug 2 If necessary add oil Clean the filler plug and install the filler plug 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 you are operating with the increased oil quantity prolonged operation in some machines can
30. Bearing Block Seal Replace ceee 129 Cooling System Coolant Extender ELC Add 137 Cooling System Water Temperature Regulator Replace tenre asennad 139 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 135 Overhaul Fuel Lines Replace ecceceeeeeeeeeeeeeeees 161 128 Maintenance Section Backup Alarm Test SEBU7764 10 102035368 Backup Alarm Test SMCS Code 7406 081 Illustration 157 g01047701 The backup alarm is located at the rear of the machine Turn the engine start switch to the ON position in order to perform the test Apply the service brakes 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 The backup alarm has one sound level The sound level is not adjustable 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 Disconnect the negativ
31. Clean 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 315 g00566124 Typical example Use a pole with a squeegee in order to reach the high areas of the window
32. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved A e o SEBU7764 10 CATERPILLAR See Operation and Maintenance Manual D10T Track Type Tractor RJG1 Up D10T 126 Maintenance Section Maintenance Interval Schedule SEBU7764 10 104038200 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 Refer to the maintenance procedure for any other exceptions that may change the maintenance intervals Note Before each consecutive interval is performed all maintenance from the previous interval must be performed Note If Cat HYDO Advanced hydraulic oils are used the hydraulic oil change interval is extended to 3000 hours S O S
33. Oil Level Check If Equipped SMCS Code 7206 535 FLV Note If your machine is equipped with this arrangement perform this procedure every 10 service hours or daily which ever occurs first Illustration 218 g01054187 1 Open the access door on the left side of the cab fs Illustration 219 g01054288 2 Check the oil level and fill oil reservoir 2 Remove the oil filler cap in order to add the oil to the oil reservoir 102093902 Equalizer Bar End Pins Measure SMCS Code 7206 082 tee i ee A ws Fe MORES akn ON Illustration 220 g00517058 To check the equalizer bar end pin for movement and unusual wear perform the following steps Note All weight of the machine must be removed from the equalizer bar Equalizer bar must have free movement in order to be measured 1 Clean the areas that are around the end pin with a high pressure wash Inspect the condition of the seal SEBU7764 10 155 Maintenance Section Ether Starting Aid Cylinder Replace 2 Check the area for oil leakage and a neutral seal position 3 Install a dial indicator and measure the vertical play at both end pin joints 4 Check the oil in both end pin joints Note Schedule the end pin joint fo
34. S oil analysis is not available the hydraulic oil change interval must remain at every 2000 Service Hours or 1 Year Refer to the Operation and Maintenance Manual Hydraulic System Oil Sample Obtain 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 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 Dispose of all fluids according to local regulations and mandates Operate the machine in order to warm the oil Park the machine on level ground Lower the blade to the ground and apply slight downward pressure Engage the parking brake and stop the engine The hydraulic tank is located on the right side of the cab g01053702 Illustration 249 1 Remove the pressure in the hydraulic tank Press the stem in
35. SEBU7764 10 13 Install the filler cap 14 Start the engine Run the engine for a few minutes 15 Maintain the oil level to the FULL mark in the sight gauge 3 Add oil if necessary 16 Stop the engine 102055215 Hydraulic System Oil Filter Pilot Replace SMCS Code 5068 510 5068 510 PS 5092 510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar 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 g01059883 Illustration 250 The pilot oil filter is located inside the access panel 1 on the right side of the machine ELIT AAG Illustration 251 g01060020 1 Remove the filter element 2 Dispose of the used filter element properly 2 Install a new filter element 3 Start the machine Allow the hydraulic oil to warm 4 Check the machine for leaks Repair any leaks if necessary i02277262 Hydraulic System Oil Filters Replace SMCS Code 5068 510 At operating temperature
36. Spring Compartment Oil Level Check 187 Every 1000 Service Hours or 6 Months Battery INSPOCt o oo er rE 128 Power Train Oil Change 181 Power Train System Screens Clean 185 Rollover Protective Structure ROPS Inspect 190 Every 2000 Service Hours or 1 Year Engine Mounts and Equalizer Bar Inspect 144 Final Drive Oil Change eeeceeeeeeeteeeeeetees 156 Final Drive Seal Guard Packing Replace 158 Hydraulic System Oil Change cece 173 Hydraulic System Oil Filter Pilot Replace 174 Ladder Hinge Oil Change s es 178 Track Roller Frame Inspect ceeeeee 195 Track Roller Frame Guides Inspect 195 Every Year Cooling System Coolant Sample Level 2 Obtain iiti entrar i ea ea 138 Engine Air Filter Primary and or Secondary Element Clean Replace 0 0 2 2 cccceeeeeeeececceeeeeeeteeeeeeeseees 141 Refrigerant Dryer Replace s an 188 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace cccccceeeeeeeeeeeeseeeeteeeees 191 Every 4000 Service Hours Electronic Unit Injector Inspect Adjust 141 Engine Mounts and Crankshaft Vibration Damper SPECE sorsien niare aaan aeiae 144 Engine Valve Lash Check Adjust eeee 152 Engine Valve Rotators Inspect eee 152 Every 6000 Service Hours or 3 Years
37. abel for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension 102429594 Seat Belt Replace SMCS Code 7327 510 Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor 1 2 JINE moe 4 g01152685 Illustration 290 1 Date of installation retractor 2 Date of installation buckle 3 Date of manufacture tag fully extended web 4 Date of manufacture underside buckle Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware 192 Maintenance Section Torque Converter Scavenge Screen Clean SEBU7764 10 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 th
38. aintenance 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 Model Specific Coolant Information or consult your Caterpillar dealer Use a 8T 5296 Coolant Test Kit to check the concentration of the coolant Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand Cooling System Conditioner contains alkali Avoid contact with skin and eyes Illustration 182 g01113678 1 The access door for the radiator cap and the sight glass for the coolant is located on the top left of the engine enclosure Loosen the radiator cap 1 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 contained during performance of inspection maintenance test ing adjust
39. als 1 Close the battery access cover 102781917 Bearing Block Seal Replace RJG1 528 SMCS Code 1359 510 SA In order to replace the Seals in the Bearing Block of the Air To Air Aftercooler refer to Disassembly and Assembly RENR3923 00 Bearing Block Fan Drive Disassemble and Disassembly and Assembly RENR3923 00 Bearing Block Fan Drive Assemble 102204803 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 If a new belt is installed check the belt adjustment after 30 minutes of operation A belt is considered to be used after 30 minutes of operation Alternator Belt a Illustration 159 g01052350 1 Open the access door 2 and hinged plate 1 on the right side of the engine Illustration 160 g01052245 2 Inspect the condition of the belt 6 and the adjustment of the belt If the belt is cracked or frayed replac
40. ant is located on the top left of the engine enclosure Illustration 183 g01113678 1 Observe the sight glass 2 in order to verify the level of the coolant If the coolant is above the middle of the sight glass the coolant level is correct If the coolant level is below the middle of the sight glass the coolant level is low 2 If it is necessary to add coolant remove the radiator cap 1 slowly in order to relieve the pressure 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 5 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 102319439 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 an
41. case with oil Either condition can cause engine damage SK A g01047439 Illustration 201 1 Open the access cover on the left side of the machine OS Py RD SAN Ae Ta ik Illustration 202 g01218549 Note Your machine is equipped with one of the two dipsticks that are shown SAFE OPERATING RANGE ADD 7 FULL LOW IDLE Illustration 203 g01223388 A Full mark at the engine running position LOW IDLE 5 SAFE STARTING RANGE B ADDI FULL ENGINE STOPPED g01218685 Illustration 204 B Full mark with cold engine oil ENGINE STOPPED 2 Check the SAFE OPERATING RANGE side or the LOW IDLE side of dipstick 1 while the engine is running at low idle The oil should be at operating temperature Maintain the oil level to the FULL mark Check the SAFE STARTING RANGE side or the ENGINE STOPPED 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 or LOW IDLE zone of the dipstick 3 Remove oil filler cap 2 If necessary add oil 4 Clean the oil filler cap and install the oil filler cap 5 Close the access cover 148 Maintenance Section Engine Oil Sample Ob
42. chine is equipped with this arrangement perform this procedure every 250 service hours Illustration 216 g00519704 7H 1680 Lubrication Pump 3 z 4 A 1 1 Illustration 217 g00304125 Equalizer bar end pin for S N 3KR617 Up machines 1 Clean the area that surrounds the end pin with a high pressure washer Inspect the condition of seal 1 2 Check the area around the seal for oil leakage Check the seal for a neutral seal position 3 Remove plug 2 154 Maintenance Section Equalizer Bar End Pins Oil Level Check SEBU7764 10 4 Apply the gear oil through fitting 3 Fill with gear oil until the gear oil reaches oil level 4 at the top of the hex head on the fitting Remove any excess oil This will maintain a volume of air Refer to Caterpillar Machine Fluids Recommendation SEBU6250 for the appropriate oil viscosity that is suited to the ambient air temperature The gear oil must be applied with a 7H 1680 Lubrication Pump or a suitable grease gun Use SAE 90 API GL 5 gear oil 85W90 API GL 5 gear oil 80W90 API GL 5 gear oil or 75W90 API GL 5 gear oil The gear oil has excellent load carrying capacity 5 Install plug 2 Note THE USE OF GREASE MPGM IS ONLY ALLOWED FOR A FAILED SEAL THE SEAL SHOULD BE REPLACED AS SOON AS POSSIBLE THE COMBINATION OF GEAR OIL AND MPGM IS NOT HARMFUL TO THE MACHINE Equalizer Bar End Pins
43. ctive Structure ROPS for bolts that are loose or damaged Replace any damaged bolts and any missing bolts with original replacement parts only Do not weld reinforcement plates to the ROPS in order to straighten the ROPS Do not weld reinforcement plates to the ROPS in order to repair the ROPS Note Notify your Caterpillar dealer if broken bolts are found Reference See Specifications in the Service Manual for information on the bolt torque if necessary 102429589 Seat Belt Inspect SMCS Code 7327 040 Always check the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine Replace any parts that are damaged or worn before you operate the machine Illustration 289 g00932801 Typical example Check the seat belt mounting hardware 1 for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight Check buckle 2 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect the seat belt 3 for webbing that is worn or frayed Replace the seat belt if the seat belt is worn or frayed Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware Note Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date l
44. d 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 103996833 Power Train Breather Clean SMCS Code 3030 070 BRE g01133444 Illustration 259 1 Open the access door on the left side of the cab g01219168 Illustration 260 2 Remove the breather 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 locat
45. d customers NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before 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 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 SEBU7764 10 139 Maintenance Section Cooling System Water Temperature Regulator Replace 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
46. drain hose 4 on the outside of the machine 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 2 Open drain valve 3 under water separator bowl 2 The water separator bowl is under the primary fuel filter 3 Remove primary filter element 1 and water separator bowl 2 Make sure that all of the old filter seals are removed from the filter base 4 Remove the water separator bowl from the primary filter element 5 Wash the water separator bowl in a clean nonflammable solvent Use pressure air to dry the water separator bowl SEBU7764 10 165 Maintenance Section Fuel System Secondary Filter Replace Oo Install clean water separator bowl 2 onto a new primary filter element 1 Only hand tighten the water separator bowl When the seal contacts the base tighten the water separator bowl for an additional 1 4 turn N Clean the filter base Coat the seal of the new primary filter element with clean dies
47. e 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 102063657 Battery Inspect SMCS Code 1401 040 eS i Oo ie AIS EN TENSA SWESS Mol Wi W T W c T il ic tl We SW T T T T W W Illustration 158 g01057538 1 Terminals and Terminal Covers 2 Retainers Note Perform the following procedures at every 1000 hour interval Check the following areas more often as required 1 Open the battery access covers The battery access covers are on the left and right side of the machine next to the operator compartment 2 Tighten the battery retainers on all batteries at every 1000 hour interval SEBU7764 10 129 Maintenance Section Bearing Block Seal Replace 3 Clean the top of the batteries with a clean cloth Keep the terminals clean and coat the terminals with petroleum jelly Install the terminal covers after you coat the termin
48. e detailed information on testing and inspection see Special Publication SEBD0518 Know Your Track Type Tractor Cooling System Replacing the Aftercooler Core in the Top Hood 1 Close the plates on the bottom of the aftercooler and attach the bolts 2 Place the manifolds on the aftercooler and attach the bolts 3 Reattach the air ducts and tighten the clamps 4 Reattach the access panels 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 environment Blow out the cores with compressed air Move the air nozzle in a systematic pattern so that the air flow covers the whole core that includes areas in the corner Clean the middle space between the aftercooler core 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 s
49. e drain valve in the transmission Install a 12 7 mm 50 inch pipe into the transmission valve Use a 12 7 mm 50 inch pipe with 1 2 14 NPTF threads 6 Clamp a hose to the pipe in order to drain the oil into a suitable container 7 Open the drain valve and drain the oil into a suitable container 8 Close the drain valve in the transmission case 9 Remove the hoses and remove the pipes from the drains 10 Remove the swivel or remove the pipe from the drain in the bevel gear case The drain valve will close 11 Clean the oil drain plugs and install the oil drain plugs 12 Change the filter element See Operation and Maintenance Manual Power Train Oil Filter Replace A TT i H i l PERENE l Illustration 268 g01307684 13 Open the left engine compartment for the transmission oil filler cap SEBU7764 10 183 Maintenance Section Power Train System Oil Level Check 14 Remove the transmission oil filler cap 2 15 Add oil To determine the correct amount of oil see Operation and Maintenance Manual Capacities Refill 16 Clean the transmission oil filler cap and install the transmission oil filler cap VOIL AT OPERATING TEMP YQ OPR ZONE 30L We ENGINE STOPPED COLD OIL 2 OPR ZONE 30L a Illustration 269 g006 11366 17 Maintain the oil level in the OPR ZONE on the dipstick 1 Close the access door 1036528
50. e of the cooling sys tem The access door for the cooling system filler cap is located on top of the engine enclosure on the left side 136 Maintenance Section Cooling System Coolant ELC Change SEBU7764 10 A a D H ON M g01113481 Illustration 178 1 Slowly loosen filler cap in order to relieve system pressure Remove the filler cap oo A Illustration 179 g01048307 2 Remove the access cover for the coolant drain The cover is located in the front bottom guard oO O Tm Illustration 180 g01113507 Bottom view 3 Remove the plug from the drain valve Install a 12 7 millimeter 5 inch pipe into the drain valve The pipe requires 1 2 14 NPTF threads Clamp a hose to the pipe in order to direct the coolant into a suitable container 4 Open the drain valve Allow the coolant to drain into a suitable container 5 Flush the system with water Flush the system until the draining water is clear Note If the cooling system is already using ELC cleaning agents are not required to be used at the specified coolant change interval Cleaning agents are only required if the system has been contaminated by the addition of some other type of coolant or by cooling system damage Clean water is the o
51. e the belt Use a Kent Moore Company BT 33 97 gauge to check the tension of the alternator belt Refer to the following table for belt tension Table 18 Belt Tension Belt Tension Initial Used 578 111 N 130425 lb 445 44 N 100 9 9 Ib 3 In order to adjust the belt tension loosen the adjusting locknut 3 and the mounting bolt 5 4 Turn the nut 4 until the correct tension is reached 5 Tighten the adjusting locknut and tighten the mounting bolt 6 Recheck the belt tension If the amount of tension is incorrect repeat the adjustment procedure 130 Maintenance Section Braking System Test SEBU7764 10 Air Conditioner Belt If Equipped A bal SSS SWS Waah Zoo e Illustration 161 g01052830 1 Open the access door 7 and hinged plate 8 on the left side of the engine Illustration 162 g01052915 2 Inspect the condition of the belt 12 and the adjustment of the belt If the belt is crack
52. e torque converter scavenge screen 1 Remove the bottom guard in order to gain access to the torque converter Note Drain all fluids into a suitable container Ey 7 A m Illustration 291 g01387611 2 Remove the bolts and drain valve body 1 from the torque converter as shown 3 Remove torque converter scavenge screen 2 from the torque converter housing 4 Wash the screen in a clean nonflammable solvent 5 Install torque converter scavenge 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 103678988 Track Check Adjust SMCS Code 4170 036 Illustration 292 g01048969 Check the track adjustment Check the track for wear and for excessive dirt buildup Grease is under high pressure Grease coming out of the relief valve under pres sure can penetrate the body causing injury or death Do not watch the relief valve to see if grease is es caping Watch the track or track adjustment cylin der to see if the track is being loosened Loosen the relief valve only one turn 1 Move the machine forward Allow the machine to coast to a stop without the use of the service brakes Adjust the tracks while you are in the machine s typical operating conditions If packing conditions prevail on the
53. eals 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 5 Install new seals and install new temperature regulators Install a new housing gasket 6 Install the regulator housing and install the elbows 103204387 Cutting Edges and End Bits Inspect Replace SMCS Code 6801 040 6801 510 6804 040 6804 510 A Illustration 187 g01051836 1 Raise the bulldozer blade and block up the bulldozer blade When you remove the cutting edges and the end bits maintain the bulldozer blade at a minimum height 2 Remove the bolts Then remove the cutting edge and the end bits 3 Thoroughly clean all contact surfaces 4 Inspect the opposite side of the cutting edge If the opposite side of the cutting edge is not worn turn the opposite side of the cutting edge outward and install the cutting edge 5 If both sides of the cutting edge are worn install a new cutting edge section Note When the cutting edge is within 10 mm 0 4 inch of the bottom of the support change the cutting edge Do not allow wear to occur on the support 6 If the bottom edge or the outside edge of the end bit
54. ed or frayed replace the belt Use a Kent Moore Company BT 33 97 gauge to check the tension of the alternator belt Refer to the following table for belt tension Table 19 Belt Tension Belt Tension Initial Used 578 111 N 130 251b 445 44N 100 9 9 Ib 3 In order to adjust the belt tension loosen the adjusting locknut 10 and the mounting bolt 11 4 Turn the nut 9 until the correct tension is reached 5 Tighten the adjusting locknut and tighten the mounting bolt 6 Recheck the belt tension If the amount of tension is incorrect repeat the adjustment procedure 102036069 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 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 bra
55. ed 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 SEBU7764 10 157 Maintenance Section Final Drive Oil Sample Obtain Illustration 224 g00937314 1 Position one final drive so that oil level mark 1 is horizontal with the oil filler plug 2 2 Remove oil filler plug 2 3 The oil level should be at the bottom of the filler plug opening Add oil if necessary 4 Wipe the magnet in order to clean the plug 5 Install oil filler plug 2 6 Repeat Step 1 to Step 5 in order to check the oil level in the other final drive 101835051 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 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 Caterp
56. eduled basis could cause severe engine dam age NOTICE Replace the thermostat on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system A new thermostat should be installed after the cooling system has been cleaned Install the thermostat while the cooling system is completely drained or while the cooling system coolant is drained to a level that is below the thermostat housing 140 Maintenance Section Cutting Edges and End Bits Inspect Replace SEBU7764 10 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 186 g01051918 1 The housing for the temperature regulators is located on the front of the engine 2 Remove the bolts 1 and 3 from the elbows Remove the elbows 3 Remove the bolts 2 from the temperature regulator housing 4 Remove the two temperature regulators and the s
57. el fuel Install primary filter element 1 onto the filter Only hand tighten the primary filter element When the seal contacts the base tighten the primary filter element for an additional 1 3 to 1 2 turn 10 Place drain hose 4 in position 11 Close drain valve 3 12 Open the fuel shutoff valve 102437924 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 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 Note Before you replace the secondary fuel filter element replace the primary fuel filter element Illustration 236 g
58. er Primary and or Secondary Element Clean Replace 2 Remove the air cleaner cover 1 Pull out in order to remove the element 3 Remove the primary filter element 2 from the air cleaner housing 4 Mark the secondary filter element in order to show that the primary filter element has been serviced The secondary filter element should be replaced when the primary filter element is serviced for the third time Refer to the section Secondary Filter Illustration 189 g00470857 5 Clean the inside of the air cleaner housing Keep the secondary filter element in place while you clean the housing 6 If the primary filter element has not been cleaned six times inspect the primary filter element If the primary filter element has been cleaned six times replace the primary filter element Proceed to Step 9 7 Inspect the primary filter element Inspect the filter element for holes and for tears by looking through the filter element Look toward a bright light Inspect the element for damaged gaskets or for dented metal parts Replace damaged filters Always crush damaged filter elements Properly discard the filter elements If you replace the primary filter element proceed to step 9 8 If the primary filter element is not damaged and the element has not been previously cleaned six times clean the element The filter element can be cleaned by using pressure air Use a maximum air pressure of 205 kPa 30 psi
59. eservoir 2 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 SEBU7764 10 187 Maintenance Section Radiator Core Clean 102612642 Radiator Core Clean SMCS Code 1353 070 1805 070 1810 070 Illustration 278 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 102055608 Radiator Pressure Cap Clean Replace SMCS Code 1353 070 Z2 1353 510 Z2 Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure The radiator cap is located inside the access door on top of the engine enclosure on the left side e E g01048235 sa A Illustration 279 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
60. eteeeseneeeaees 198 Every 10 Service Hours or Daily Backup Alarm Test 2 ceceeceeeeeeeeeeeteeeees 128 Braking System Test a an 130 Cab Filter Fresh Air Clean Inspect Replace 131 Cooling System Coolant Level Check 138 Engine Oil Level Check ccc ceeeeeeeeteeeeneeees 147 Fuel Tank Water and Sediment Drain 167 Horn TeSt a EE ees caveen EA 169 Hydraulic System Oil Level Check 5 176 Indicators and Gauges Test 2 177 Power Train System Oil Level Check 183 Pivot Shaft Oil Level Check eeeeee 186 Seat Belt Inspect 20 eee ee eeeeeeeeecteeeeeeeeees 191 Walk Around Inspection eeeseeeeeeeeeees 196 Every 50 Service Hours Bulldozer Tilt Brace and Tilt Cylinders LUDIICATG ses tects E E N E T EA 131 Lift Cylinder Yoke Bearings Lubricate 178 Ripper Linkage and Cylinder Bearings LUDFIGALC ve o is ee tis ana ETSA 189 Track Pins Inspect cecceeeeeeeeeeeeeeseetreaeees 195 Every 50 Service Hours or Weekly Cab Filter Recirculation Clean Inspect Replace ET E EA E 132 Initial 250 Service Hours or at first oil change Power Train Oil Filters Replace 2005 180 Every 250 Service Hours Belts Inspect Adjust Replace eee 129 Engine Oil Sample Obtain asais 148 Engine Oil and Filter Change n se 149 Equa
61. h 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 transmission oil clean the scavenge screens Transmission g02161128 Illustration 274 1 Remove the plug from the drain valve in the transmission cover 1 Install a 12 7 mm 50 inch pipe with 1 2 14 NPTF threads into the valve 2 Clamp a hose to the pipe in order to drain the oil into a suitable container 3 Open the drain valve and drain the oil into a suitable container 4 Close the drain valve 5 Remove the hose and remove the pipe from the drains 6 Remove the bolts for the drain cover 2 and remove the drain cover 3 Remove the seal and remove the screen that is located behind the cover 7 Wash the screen in a clean nonflammable solvent 8 Inspect the seal If the seal is damaged replace the seal 9 Install the screen the seal and the drain cover on the transmission 10 Clean the oil drain plug and install the oil drain plug Suction Screen The suction screen for the power tra
62. he bulb from the HID lamp 4 Install the replacement bulb in the HID lamp If the bulb is an integral part of the lens assembly install the replacement lens assembly in the HID lamp Note In order to avoid failure to the bulb that is premature avoid touching the bulb s surface with your bare hands Clean any fingerprints from the bulb with alcohol prior to operation 5 Reassemble the housing for the HID lamp Ensure that any printing on the lens is oriented correctly with respect to the HID lamp s mounting position on the machine 6 Reattach the electrical power to the HID lamp 7 Check the HID lamp for proper operation Note Consult your Caterpillar dealer for additional information on HID lamps 102054663 Horn Test SMCS Code 7402 081 Test the horn on a daily basis Press downward on the horn button in order to sound the horn If the horn does not sound make the necessary repairs before you operate the machine 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 po
63. he manifolds off the aftercooler core Lay the manifolds to the side 5 Remove the bolts from the plates that are on the bottom of the aftercooler 6 Open the plates 7 Inspect the aftercooler Aftercooler RJG529 Up ny Th be Illustration 171 g01219189 Rear view of dual aftercooler RJG529 Up Radiator Core g00827864 Illustration 172 134 Maintenance Section Cooler Cores and A C Condenser Clean SEBU7764 10 A C Condenser Core el gi re o a ne i o Illustration 173 g01060198 A common arrangement for the air conditioner condenser is located behind the radiator Illustration 174 g01224464 Another arrangement for the air conditioner condenser is located under the hood Remote A C Condenser Core In some machine arrangements the a c condenser core is remotely located A remote mounted a c condenser core is cooled by fans with electric drive ae ooo ma is Illustration 175 g01053048 An optional arrangement for the air conditioner condenser is located on the right side fender Illustration 176 g01117129 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
64. ides Inspect SMCS Code 4177 040 Measure the rotational movement of the front roller frame relative to the rear roller frame Ap O 5 A A P z je E g01049094 Illustration 304 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 196 Maintenance Section Walk Around Inspection SEBU7764 10 g01049245 Illustration 305 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 AA ER a a g01049226 Illustration 306 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 307 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
65. if the seals are damaged Illustration 253 g01053837 4 Remove the rods 7 and 9 that retain the filter elements Unscrew the nuts that are located at the bottom of the rods Remove the filter elements 6 and 8 by sliding the filters off rods 7 and 9 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 Nem 7 4 1 1 Ib ft 5 Place filters back into the hydraulic tank 6 Wash the covers in a clean nonflammable solvent 7 Install the seals and the covers 8 Maintain the hydraulic oil to the FULL mark in the sight gauge 5 176 Maintenance Section Hydraulic System Oil Level Check SEBU7764 10 102195781 Hydraulic System Oil Level Check SMCS Code 5056 535 FLV 7479 At operating temperature the hydraulic tank is hot and under pressure Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand Remove the filler cap slowly in order to relieve pressure Lower the bulldozer and the ripper to the ground The hydraulic tank is on the right side of the cab g01053736 Illustration 254 1 Maintain the oil level to the FULL mark in the sight gauge 3 Put the tilt cylinders in the center position before yo
66. illar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Obtain the sample of the differential and final drive oil as close as possible to the recommended sampling interval The recommended sampling interval is every 500 service hours In order to receive the full effect of S O S oil analysis you must establish a consistent trend of data Illustration 225 g00937447 1 Position one final drive so that oil level mark 1 is horizontal Drain plug 3 should face downward 2 Remove oil filler plug 2 and obtain the oil sample with a proper suction device 3 Install oil filler plug 2 4 Repeat Step 1 through Step 3 in order to sample the oil in the other final drive 158 Maintenance Section Final Drive Seal Guard Inspect Clean SEBU7764 10 102211034 Final Drive Seal Guard Inspect Clean If Equipped SMCS Code 4052 040 4052 070 Note The final drive seal guards may need to be inspected more frequently than the standard 500 service hour interval when the machine is operated in very severe applications Adjust the interval if necessary Illustration 226 g00941487 1 Guard 2 Inspection cover 1 Remove the inspection cover 2 on the guard 1 2 Inspect the condition of the final drive underneath
67. ilter element housings a Torque the filter element housings to 61 7 N m 45 5 Ib ft 6 Start the engine 7 Check the transmission oil level Refer to Operation and Maintenance Manual Transmission Oil Level Check for details Lower the Transmission Guard if equipped 1 To lower transmission guard 3 support the guard with the proper lifting device 2 Position handle 2 to area B 3 Lower the transmission guard Install the secondary bar pin the washer and lock pin bolt 1 to the brackets 4 Return handle 2 to position A 103965831 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 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 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 s
68. in and equalizer bar im t lo g o 0 A GO LY Illustration 198 g01108803 2 Put a 55 ton hydraulic jack in position under the main frame as shown Illustration 199 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 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 200 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 SEBU7764 10 147 Maintenance Section Engine Oil Level Check 102438636 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 crank
69. in is located below the cab 186 Maintenance Section Pivot Shaft Oil Level Check SEBU7764 10 Illustration 275 g02161135 1 Remove the bolts 4 and remove the cover 5 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 transmission with oil Refer to Operation and Maintenance Manual Power Train Oil Level Check and Operation and Maintenance Manual Capacities Refill 102927165 Pivot Shaft Oil Level Check SMCS Code 4153 535 FLV Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Note The initial fill of pivot shaft may trap air in the tube The level of the oil may fall as air escapes Barometric pressure and altitude changes may also cause the oil level to raise or lower The reservoir must be filled several times in order to remain consistently full Illustration 276 g01054187 Open the access door on the left side of the cab 1 f Ng PS p a Illustration 277 901154544 Maintain the oil within the limits of the dipstick for the oil r
70. ine 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 SE 1054 510 PY Primary Filter NOTICE Service the primary filter element only when the alert indicator for the intake air filter is flashing Do not open the filter compartment unless it is time for service Opening the filter compartment can cause dirt to get into the clean side of the filter housing NOTICE Extremely short air filter life can result if the preclean er system malfunctions If air filter life is drastically re duced from typical for the operating conditions con sult your Caterpillar Dealer The exhaust system dust ejector for the strata tube precleaner must pull a min imum vacuum of 508 mm 20 inch of water NOTICE Service the engine air filters with the engine stopped Engine damage could result NOTICE Always leave the secondary filter element in place while you clean the primary element or while you clean the air cleaner housing NOTICE Do not use the filter for longer than one year 1 Open the engine compartment s access door if equipped Illustration 188 g00470852 142 Maintenance Section SEBU7764 10 Engine Air Filt
71. ing 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 3 00 L 100 oz of Extender to the cooling system 4 Observe the sight glass 2 in order to verify the level of coolant If the coolant level is at the middle of the sight glass the coolant level is correct If the coolant level is below the middle of the sight glass the coolant level is low 5 Replace the radiator cap if the cap gasket is damaged Install the radiator cap 138 Maintenance Section Cooling System Coolant Level Check SEBU7764 10 102205428 Cooling System Coolant Level Check SMCS Code 1353 535 FLV 1395 535 FLV At operating temperature the engine coolant is hot and under pressure Steam can cause personal injury Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand Remove the fill cap slowly to relieve pressure Cooling system conditioner contains alkali Avoid contact with the skin and eyes to prevent personal injury The access door for the radiator cap and the sight glass for the cool
72. ion is inside the enclosure above the left fender Illustration 261 g02174560 180 Maintenance Section Power Train Oil Filters Replace SEBU7764 10 Open the access door to the left side enclosure as shown Unscrew and remove the transmission breather 1 Perform steps 2 to 4 103652871 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 The transmission and torque converter oil filters are under the fuel tank on the rear of the machine Lifting the Transmission Guard if equipped 1 If the machine is equipped with a transmission guard support the transmission guard with the proper lifting device Illustration 262 g00610821 Rear view of machine 2 Remove the lock pin bo
73. is worn install a new end bit SEBU7764 10 141 Maintenance Section Electronic Unit Injector Inspect Adjust Note When the end bit is within 10 mm 0 4 inch of the bottom of the support change the end bit When the end bit is within 10 mm 0 4 inch of the outside edge of the support change the end bit Do not allow any wear to occur on the support 7 Install all bolts and tighten the bolts to the specified torque Reference For more information refer to Specifications Torque Specifications 8 Raise the bulldozer blade and remove the blocking Lower the bulldozer blade to the ground 9 After you operate the machine for a few hours check all bolts for the proper torque 102061807 Electronic Unit Injector Inspect Adjust SMCS Code 1290 025 1290 040 The Electronic Control module produces high voltage To prevent personal injury make sure the Electronic Control Module is not powered and the unit injector solenoids are disconnected NOTICE The camshafts must be correctly timed with the crank shaft before an adjustment of the unit injector lash is made The timing pins must be removed from the camshafts before the crankshaft is turned or damage to the cylinder block will be the result The operation of Caterpillar engines with improper adjustments of the electronic unit injector can reduce engine efficiency This reduced efficiency could result in excessive fuel usage and or shortened eng
74. ithout the fast fill fuel adapter require a vented fuel cap TATTOO 02 CAT 5 oa Illustration 240 g01110732 SEBU7764 10 167 Maintenance Section Fuel Tank Water and Sediment Drain 1 Lift lever 5 in order to remove the fuel tank filler cap Turn the lever counterclockwise until the lever stops Lift the cap straight up in order to remove the cap 2 Remove the fuel strainer from the filler neck 3 In order to replace the filter assembly remove two screws that secure filter assembly 4 to the fuel cap Remove filter assembly 4 valve 3 and the gaskets 4 Wash the cap and the strainer in a clean nonflammable solvent 5 Inspect the tank cap seal If the seal is damaged replace the seal 6 Replace the filter assembly the valve the gaskets and the screws Use a 9X 2205 Cap Filter Kit 7 Install the strainer 8 Install the fuel cap Rotate the fuel cap clockwise until three tabs 7 drop into the slots in the adapter Rotate lever 5 clockwise until the lever stops Lower lever 5 over locking tab 6 Fast Fill Fuel Adapter If Equipped See illustration 239 Machines that are equipped with a fast fill fuel adapter 2 have identical fuel caps as systems without a fast fill fuel adapter Use the same procedure for changing the filter in the two systems 102784163 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S NOTICE Care must
75. ke 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 Illustration 163 g01017767 1 Start the engine 2 Raise all attachments 3 Depress the brake pedal 4 Release the parking brake switch SEBU7764 10 131 Maintenance Section Bulldozer Tilt Brace and Tilt Cylinders Lubricate 5 While the brake pedal is depressed move the directional control lever to the THIRD SPEED FORWARD position 6 Gradually increase the engine speed to full load speed The machine should not move 7 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 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 164 g02158909 One grease fitting is located at the left front brace assembly or left tilt cylinder if equipped 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 10342
76. l the new oil 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 installation instructions that are provided by the supplier of the filter 9 Install the crankcase drain plug 10 Remove oil filler cap 7 Fill the crankcase with new oil See Operation and Maintenance Manual Capacities Refill Clean the oil filler cap and install the oil filler cap 11 Always measure the oil level with dipstick 6 in order to ensure that the correct amount of oil was added 12 Start the engine in order to warm the oil Note Your machine is equipped with one of the two dipsticks that are shown SAFE OPERATING RANGE ADD J FULL LOW IDLE Illustration 211 g01223388 A Full mark at the engine running position LOW IDLE 13 Check the SAFE OPERATING RANGE side or the LOW IDLE side of the dipstick while the engine is running The oil should be at operating temperature Maintain the oil level in the SAFE OPERATING RANGE or the LOW IDLE range 14 Close the engine access door on the left side of the machine 152 Maintenance Section Engine Valve Lash Check Adjust SEBU7764 10 102092049 Engine Valve Lash Check Adjust SMCS Code 1102 025 To prevent possible injury do not use the starter motor to turn the flywheel Hot engi
77. leaks around the covers and around the hoses Repair any oil leaks 102094238 Winch Wire Rope Install If Equipped SMCS Code 5154 012 5163 012 Personal injury or death can result from worn wire rope cable Worn or frayed cable could break causing injury Check the wire rope cable If cable is worn or is frayed install a new cable PA140VS The cable is attached to the drum on the winch with a cable ferrule The ferrule is placed into a socket on the drum Use the following table to order the cable Table 23 Wire Cable Wire Rope Recommended Holding Capacity Diameter Ferrule 25 mm 1 inch L 8 91 m 300 ft 29 mm J 9 84 m 276 ft 1 13 inch 32 mm J 10 59 m 193 ft 1 25 inch Illustration 311 g01076208 1 Put the cable in a straight line behind the tractor 2 Install the ferrule end into the socket 3 Reel in the cable 198 Maintenance Section Window Washer Reservoir Fill SEBU7764 10 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 Ea Illustration 312 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 102039002 Window Wipers I
78. lizer Bar End Pins Oil Level Check 153 Final Drive Oil Level Check ceeeeeee 156 Ladder Adjust 0 ee ceeeeeeeeeeeeeeeseeeeeeeeeeeeeaeees 177 Track Check AdjuSt 0 ceccceeeeseeeeeeetnteeeeeeeaes 192 Winch Fairlead Rollers Lubricate 196 Winch Oil Level Check eeceeeeeeeeeeereeees 197 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 OD aN e aea EERE EA E 138 Electronic Unit Injector Inspect Adjust 141 Engine Valve Lash Check Adjust eeeee 152 Engine Valve Rotators Inspect eeeee 152 Every 500 Service Hours Engine Crankcase Breather Clean aansien 143 Final Drive Oil Sample Obtain 08 157 SEBU7764 10 127 Maintenance Section Maintenance Interval Schedule Final Drive Seal Guard Inspect Clean 158 Fuel System Primary Filter Clean Replace 164 Fuel System Secondary Filter Replace 165 Fuel Tank Cap Filter and Strainer Replace Clean stidan irkaii eade 166 Hoses and Clamps Inspect Replace 169 Hydraulic System Oil Filters Replace 174 Hydraulic System Oil Sample Obtain 176 Power Train Breather Clean n se 179 Power Train Oil Filters Replace 08 180 Power Train System Oil Sample Obtain 184 Recoil
79. llow the established procedure using the recommend ed tooling NOTICE The machine must be parked on a level surface to perform this procedure Personal injury or death can occur from not fol lowing the proper procedure or the recommended tooling To prevent the possibility of injury or death follow the established procedure using the recommend ed tooling NOTICE The machine must be parked on a level surface to perform this procedure Note All the weight of the machine must be removed from the equalizer bar Equalizer bar must have free movement in order to be measured To check the equalizer bar end pin for movement and unusual wear perform the following steps SEBU7764 10 145 Maintenance Section Engine Mounts and Equalizer Bar Inspect Illustration 194 901108793 1 Clean the areas that are around the end pin with a high pressure wash Inspect the condition of the seal 2 Check the area for oil leakage and a neutral seal position 3 Check the oil in both end pin joints Illustration 195 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 196 g01108798 5 Put a 55 ton hydraulic jack in position under the end of the equalizer bar 6 Jack up the equalizer bar and take a reading on
80. lt secondary bar pin and washer 1 from the bracket 3 Lift transmission guard 3 from the bottom of the guard Lift the transmission guard until the end of handle 2 extends beyond the fender to position C This locks the guard in the OPEN position Replace the Transmission and Torque Converter Oil Filters l Illustration 263 g01050289 Transmission oil filter 4 Torque converter oil filter 5 Note The Caterpillar recommended filters are a special high efficiency design Use only the recommended filter SEBU7764 10 181 Maintenance Section Power Train Oil Change NOTICE The element in the transmission oil filter can become plugged with debris The flow of clean oil to the system will decrease or stop Follow maintenance recommendations to ensure ele ment will not fill up with debris NOTICE Dirty oil or debris left in the transmission filter housing during filter change can enter the transmission and cause serious damage Use a clean dry cloth to clean the bottom of the hous ing 1 Remove the filter element housing for the transmission oil filter 4 and the torque converter oil filter 5 2 Remove the filter elements and properly discard the filter elements 3 Clean the inside of the filter element housings with a clean dry cloth 4 Inspect the seals for the housings If a seal is damaged replace the seal 5 Install the new filter elements Install the f
81. ne components can cause burns Allow additional time for the engine to cool before mea suring valve clearance Electrical shock hazard The electronic unit injec tor system uses 90 120 volts NOTICE Operation of Caterpillar engines with improper valve adjustments will reduce engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life NOTICE Measure the valve clearance with the engine stopped To obtain an accurate measurement allow at least 20 minutes for the valves to cool to engine cylinder head and engine block temperature Check the valve bridge before setting the valve lash Ensure that the valve bridge is seated equally on both valve stems Refer to your machine s Service Manual or your Caterpillar dealer for the complete valve adjustment procedure 102092057 Engine Valve Rotators Inspect SMCS Code 1109 040 When inspecting the valve rotators protective glasses or face shield and protective clothing must be worn to prevent being burned by hot oil or spray Electrical shock hazard The electronic unit injec tor system uses 90 120 volts A WARNING Illustration 212 g00941949 1 Start the engine Run the engine at low idle Illustration 213 g00038585 2 Watch the top surface of each valve rotator Whenever an inlet valve closes or an exhaust valve closes each valve rotator should turn 3 If a
82. nel Fuse 26 175 Amp Fuse cover 27 Plastic Power outlet 28 12 Volt Starting Charging Analyzer 29 Plug 70 pin Connector HVAC blower 30 Reset button 15 Amp Fuse Puller 31 Auto Stop Remote Air Conditioner Condenser 32 15 Amp 102245859 High Intensity Discharge Lamp HID Replace If Equipped SMCS Code 1434 510 HID lamps operate at very high voltages To avoid electrical shock and personal injury disconnect power before servicing HID lamps SEBU7764 10 169 Maintenance Section Horn Test 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 applicable laws 1 Remove the electrical power from the high intensity discharge lamp HID The electrical power must be removed from the HID lamp for at least five minutes in order to ensure that the bulb is cool 2 Disassemble the housing for the HID lamp in order to have access to the bulb Note On some HID lamps the bulb is an integral part of the lens assembly The bulb is not removed separately from the lens assembly Replace the entire lens assembly on these HID lamps 3 Remove t
83. ng 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 282 g01054187 The in line dryer is located on left hand side of the machine in the compartment 1 with the fuel filters SEBU7764 10 189 Maintenance Section Ripper Linkage and Cylinder Bearings Lubricate The in line dryer is accessible by opening the door to the compartment Illustration 283 g01017640 Note The R 134a refrigerant dryer should be replaced annually Extremely humid operating conditions may require more frequent replacement of the dryer The dryer should also be replaced if the air conditioning system has been leaking or if the system has been opened for service repair Reference For the correct procedure refer to Air Conditioning and Heating Service Manual SENR5664 or the Disassembly and Assembly Manual for your machine Note A qualified mechanic should replace the components of the refrigerant system since special tooling and training are required
84. nly cleaning agent that is required when ELC is drained from the cooling system 6 Close the drain valve and install the plug 7 Replace the access cover 8 Add the ELC solution Refer to Operation and Maintenance Manual Capacities Refill 9 Start the engine Run the engine without the filler cap until the thermostat opens and the coolant level stabilizes Check the level of the coolant Refer to Operation and Maintenance Manual Cooling System Coolant Level Check 10 If the gasket is damaged replace the filler cap Install the filler cap 11 Stop the engine Illustration 181 g00533931 12 Clean the radiator cores with compressed air You may need to use water in order to remove debris For additional information about the coolant see Operation and Maintenance Manual SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer SEBU7764 10 137 Maintenance Section Cooling System Coolant Extender ELC Add 102205241 Cooling System Coolant Extender ELC Add SMCS Code 1352 044 Table 20 Amount of the Caterpillar Extended Life Coolant Extender by Cooling System Capacity Recommended Amount of Caterpillar Extender 3 00 L 100 oz Cooling System Capacity 115 to 163 L 30 to 43 US gal When a Caterpillar Extended Life Coolant ELC is used an extender must be added to the cooling system See the Operation and M
85. nspect Replace SMCS Code 7305 040 7305 510 4 2 oi dy 1 x e Illustration 313 g01058605 1 Front window wiper 2 Side window wiper 3 Rear 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 blades that streak the window 103131127 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 314 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 SEBU7764 10 199 Maintenance Section Windows
86. om the bottom of the guard Lift the transmission guard until the end of handle 2 extends beyond the fender to position C This locks the guard in the OPEN position Illustration 273 g01062228 4 Remove the protective cap 4 from the sampling valve Note Flush the fitting with oil into an approved container before you obtain the oil sample 5 Use the 8T 9190 Fluid Sampling Bottle in order to obtain a sample SEBU7764 10 185 Maintenance Section Power Train System Screens Clean 6 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 8T 9190 Fluid Sampling Bottle 7 Replace the protective cap 4 for the sampling valve 8 To lower transmission guard 3 support the guard with the proper lifting device 9 Position handle 2 to area B 10 Lower the transmission guard Install the lock pin bolt secondary bar pin and washer 1 to the brackets 11 Return handle 2 to position A 103965189 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 wit
87. ontaining 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 d Illustration 223 g00937318 1 Position one final drive so that oil level mark 1 is horizontal Drain plug 3 should face downward 2 Remove drain plug 3 Allow the oil to drain into a suitable container 3 Remove oil filler plug 2 in order to vent the final drive as the oil drains out of the final drive 4 Inspect the drain plug seal Replace the drain plug seal if the drain plug seal is damaged 5 Clean drain plug 3 and install the drain plug 6 Remove oil filler plug 2 7 Fill the final drive with oil to the bottom of the filler plug opening See Operation and Maintenance Manual Refill Capacities 8 Inspect the condition of the plug seal Replace the plug seal if the plug seal is damaged 9 Repeat Step 1 to Step 8 in order to change the oil in the other final drive 101834822 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 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 prepar
88. pect Replace SMCS Code 7342 040 7342 070 7342 510 The recirculation filter is located to the left of the operator s seat CYT Ue S I es Illustration 167 g01049402 1 Unscrew the bolt 1 in order to remove the filter cover 2 Remove the filter element 2 The filter element can be cleaned by using compressed 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 i03680600 Camera Clean Adjust WAVS If Equipped SMCS Code 7348 In order to maintain sufficient vision keep the Work Area Vision System WAVS camera lens and the display clean ELS TGOGSOTG Illustration 168 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 169 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
89. r repair if movement exceeds 1 50 mm 059 inch Consult your Caterpillar dealer for an inspection and for repair instructions 102210190 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 000 2n i O08
90. rack Check Adjust SEBU7764 10 Illustration 298 g00945711 2 Add multipurpose grease MPGM through track adjustment valve 6 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 5 Install access cover 5 Tight Track Adjustment Illustration 299 sy g00945717 1 Remove access cover 5 Illustration 300 g00945714 2 Loosen relief valve 7 by one turn of 360 degrees Allow the grease to escape 3 Close the relief valve Illustration 301 g00945711 4 Add MPGM through track adjustment valve 6 Add grease until dimension 2 is correct 5 Install access cover 5 Bolt Torque for Track Shoes The torque requirement for track shoe bolts is 870 70 N m 642 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 870 90 N m 642 66 lb ft Then tighten the bolts for an additional 120 degrees SEBU7764 10 195 Maintenance Section Track Pins Inspect 102039746 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
91. rder to release pressure 4 Turn the engine start switch key to OFF At operating temperature the hydraulic tank is hot and under pressure Hot oil and components can cause personal in jury Do not allow hot oil or components to contact skin Before removing the filler cap press the valve re lief button on the hydraulic tank in order to relieve the tank pressure Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand Remove the filler cap slowly in order to relieve any remaining pressure Illustration 245 g01944042 Front view of the hydraulic tank 1 Filler Cap 2 Breaker Relief Valve 3 Sight Glass 4 Drain Valve 5 Press the button on the breaker relief valve 2 in order to relieve any tank pressure Slowly remove filler cap 1 172 Maintenance Section Hydraulic System Filter Bypass Screen Clean SEBU7764 10 Illustration 246 901944045 Bottom view of the Hydraulic Tank 5 Suction for Fan Drive Pump 6 Suction for Implement Pump 7 Hydraulic tank access cover 8 Implement return port 9 Case drain return 10 Fan return 6 Drain the hydraulic oil tank at drain 4 Reference For the correct procedure refer to Operation and Maintenance Manual Hydraulic System Oil Change 7 Disconnect the drain lines 8 Unbolt hydraulic tank access cover 7 gt gt
92. reather not shown 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 the breather 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 element into the breather and install the breather 8 Install the hose onto the outlet of the breather cover and tighten the clamp 144 Maintenance Section Engine Mounts and Crankshaft Vibration Damper Inspect SEBU7764 10 102091921 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 vibrations will result in damage to the crankshaft and in damage to the other engine components A deteriorating vibration damper will cause excessive gear train noise at variable points in the speed range See the Service Manual Engine Disassembly and Assembly for the procedure to install a new damper Caterpillar recommends replacing the damper for any of the following reasons e The engine has had a failure because of a broken crankshaft The damper can be used again if none of the above conditions are found The damper can
93. rly The internal circuits the indicators and the gauges are automatically checked Illustration 256 g01106466 The operator must observe the indicators and the gauges in order to determine whether gauge modules the action light the alert indicators and the display screen 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 All indicators of units Deg C kPa rpm and liters X100 readout Symbol for the hour meter 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 speed readout 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 Stop the engine Make any necessary repairs before you operate the machine 103600040 Ladder Adjust SMCS Code 0634
94. s 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 g01053745 Illustration 255 1 Remove the protective cap from the sampling valve 1 SEBU7764 10 177 Maintenance Section Indicators and Gauges Test 2 Use 169 8373 Fluid Sampling Bottle in order to obtain the 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 correct fluid for your machine 102184397 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 The self test verifies that the monitoring panel and the display modules are operating prope
95. s is located inside the cab on the left side of the seat Open the cover for access to the circuit breakers and the fuses NOTICE Always replace fuses with the same type and capacity fuse that was removed Otherwise electrical damage could result NOTICE If it is necessary to replace fuses frequently an elec trical problem may exist Contact your Caterpillar dealer A B e Illustration 243 g01106464 A Open fuse box B 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 10 Amp Spare 6 20 Amp GPS Radio Transmission Antenna 7 15 Amp Seat Ripper or Implements 8 15 Amp Standard Converter 9 10 Amp Spare 10 15 Amp Accugrade 11 15 Amp Wipers 12 15 Amp Ignition Key 13 10 Amp Fender Floodlights 14 15 Amp Horn 15 15 Amp CAES Display 16 10 Amp Secondary Brake 17 15 Amp Unswitched Auxiliary 18 15 Amp Product Link 19 15 Amp Advisor Panel 20 15 Amp Implement ECM 21 15 Amp Implement ECM 22 15 Amp Engine ECM 23 20 Amp 24 VA 12 VA Converter 24 Attachment 20 Amp Cover 25 Fuse pa
96. services may extend the oil change even longer Consult your Caterpillar dealer for details When Required Battery Battery Cable or Battery Disconnect Switch Replace saai tn tah Soothe eee lee 128 Camera Clean Adjust ccceeeeeeeeeeettteeeeeeees 132 Cooler Cores and A C Condenser Clean 133 Cutting Edges and End Bits Inspect Replace 140 Engine Air Filter Primary and or Secondary Element Clean Replace ci iie iaaah naia iaeoe 141 Engine Air Precleaner Clean n se 143 Equalizer Bar Center Pin Measure 153 Equalizer Bar End Pins Measure 154 Ether Starting Aid Cylinder Replace 155 Fuel System Prime ccccceeceeeeeeeeeeesteeeeeeenaaes 163 Fuses and Circuit Breakers Replace Reset 167 High Intensity Discharge Lamp HID Replace 168 Hydraulic System Filter Bypass Screen Clean 171 Oil Filter Inspect c ccccceeceeeeeeteeeeeeeeeeeeeeees 178 Radiator Core Clean ccececeeeeecceceeeeeeeeeeees 187 Radiator Pressure Cap Clean Replace 187 Ripper Tip and Shank Protector Inspect Replace msitoe aleen hel Sede tite neat inet 190 Torque Converter Scavenge Screen Clean 192 Winch Wire Rope Install 0 2 0 0 197 Window Washer Reservoir Fill 0 006 198 Window Wipers Inspect Replace 0 06 198 Windows Clean eccecceeeeeeeeee
97. ssible 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 170 SEBU7764 10 Maintenance Section Hoses and Clamps Inspect Replace TOP VIEW OF ENGINE Illustration 244 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 following 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 SEBU7764 10 171 Maintenance Section Hydraulic System Filter Bypass Screen Clean 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
98. stem Prime 102440374 Fuel System Prime 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 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 Turn the ignition switch to the OFF position Illustration 233 g01133444 2 Open the access door on the left side of the cab Illustration 234 g01047632 3 Move the switch for the electric fuel priming pump to the ON position Allow the fuel priming pump to run for several seconds 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
99. tain SEBU7764 10 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 sampling interval may vary for some S O S oil analysis programs 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 Supplies for collecting samples can be obtained from your Caterpillar dealer These supplies include the following probes probe holders tubing and sampling bottles Use the following guidelines for proper oil sampling e Always take samples when the machine is at operating temperature and the oil has had time in order to circ
100. tenance Section Final Drive Seal Guard Packing Replace SEBU7764 10 Illustration 230 g00940433 9 Outer packing 10 Joint in the outer packing A Diameter A B 180 degrees 4 Install the outer packing 9 Offset the joint in the inner packing 8 and the outer packing 10 at 180 degrees Stretch the packing during installation Smooth the packing and keep the packing uniform Minimize the joint 10 at the ends of the outer packing 9 Illustration 231 g00939660 4 Bolt 5 Washer 6 Retainer 9 Outer packing 10 Joint in outer packing 11 Joint in retainers C 90 Degrees from joint in outer packing to joint in retainers Note The joint 10 in the outer packing 9 must be offset 90 degrees C to the joints 11 in the retainers 6 5 Assemble retainers 6 to seal guard 3 with washers 4 and bolts 5 The clearance at area D should be 2 mm 0 079 inch 6 Repeat steps 3 through 5 in order to replace the packing on the other final drive if necessary 7 Replace the final drive seal guards Reference Refer to Operation and Maintenance Manual Final Drive Seal Guard Inspect Clean lf Equipped for the correct procedure for installing the final drive seal guards SEBU7764 10 161 Maintenance Section Fuel Lines Replace 103897733 Fuel Lines Replace Low Pressure SMCS Code 1274 NOTICE Care must be taken to ensure
101. 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 Nonmetallic Fuel Lines Make sure to replace the nonmetallic fuel lines at the engine overhaul 162 SEBU7764 10 Maintenance Section Fuel Lines Replace TOP VIEW OF ENGINE Illustration 232 g02141035 Top view of engine 2 Remove and install the front two low pressure fuel NOTICE lines 2 with new hoses 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 and install the rear two low pressure fuel nearby components Contact with other surfaces will lines 1 with new hoses produce chafing that could lead to a leak A properly installed hose will contact only the hose clips SEBU7764 10 163 Maintenance Section Fuel Sy
102. the engine before any additional priming 6 Run the engine at the LOW IDLE position until the engine runs smoothly 7 Close the access door Note Do not activate the priming pump while you crank the engine 164 Maintenance Section Fuel System Primary Filter Clean Replace SEBU7764 10 102031921 Fuel 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 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 Illustration 235 g01047193 Close the fuel shutoff valve 5 1 Place
103. the guard Inspect the final drive for debris or abrasive substances that are wrapped around the final drive such as cable or wire 3 If the area inside the guard is packed with debris or abrasive substances remove guard 1 and clean the debris or abrasive substances from the guard and the final drive 4 Install the guard 1 onto the final drive 5 Install the inspection cover 2 on the guard 1 Reference Refer to Operation and Maintenance Manual Final Drive Seal Guard Packing Replace If Equipped for more information on the procedure to replace the packing 102782443 Final Drive Seal Guard Packing Replace If Equipped SMCS Code 4052 510 The design of the seal guard has a packing that prevents debris from entering the area of the Duo Cone Seal Gp The close fit and tolerances limit the size of the debris that can enter the labyrinth seal to 2 mm 0 079 inch The labyrinth seal changes the direction of the debris four times Contact may be made at the packing after the fourth time The packing material is impregnated with silicone oil Therefore it is not necessary to fill the cavity for the packing with grease The packing is held in place by retainers that can be removed This allows the replacement of the packing without removing the final drive The packing has a split that allows the packing to be placed over the spindle Replacement of the Packing Illustration 227 g00939700 4 Bolt
104. 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 SEBU7764 10 175 Maintenance Section Hydraulic System Oil Filters Replace 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 Dispose of all fluids according to local regulations and mandates Note The hydraulic tank is equipped with two filter elements The hydraulic tank is located on the right side of the cab 1 Lower the bulldozer and the ripper to the ground Illustration 252 g01053825 2 Check the pressure in the hydraulic tank Press the stem in the center of the valve 1 in order to relieve the system pressure 3 Remove the nuts from the covers 2 and 3 Rotate the covers counterclockwise in order to remove the covers Remove the cover seals Replace the cover seals
105. 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 103130720 Rollover Protective Structure ROPS Inspect SMCS Code 7325 040 Note The ROPS arrangement typically consists of the following components ROPS assembly 1 canopy with upper mounting bolts A and ROPS support assembly 2 with lower mounting bolts B See Illustration 288 Illustration 288 g01609177 1 Rollover Protective Structure ROPS SEBU7764 10 191 Maintenance Section Seat Belt Inspect Inspect the ROPS arrangement 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 Inspect the Rollover Prote
106. u check the oil level Check the oil level when the oil is cold Verify that the oil level is below the FULL mark before you remove the filler cap If the hydraulic system requires additional hydraulic oil perform the following procedure 1 Check for pressure in the hydraulic tank Press the stem in the center of the valve 1 2 Use caution to remove filler cap 2 Slowly remove the filler cap and add oil through the filler tube 3 Clean the filler cap and install the filler cap 102054835 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 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 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 analysi
107. ulate through the oil system e Always drain about 100 mL 4 oz of oil into a container before you take the sample This will flush the sampling valve 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 Keep the lids on empty sampling bottles until you are ready to collect the sample e Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination e Never collect samples from the drain for a system a pan of used oil or a used filter 1 Operate the machine until the machine reaches operating temperature 2 Set the engine at low idle 3 Open the access cover if equipped that is on the left side of the machine Illustration 205 g01223047 4 Clean the area around the sampling valve and the protective cap in order to avoid contamination of the sample Remove the protective cap 5 Flush the sampling valve Insert the probe into the sampling valve Collect about 100 mL 4 02 of oil into a container This will flush the sampling valve Remove the probe Note It may be necessary to increase the engine RPM if the oil flow is too slow at low idle 6 Collect the sample Do not allow dirt or other contaminants to enter the sampling bottle Insert the probe into the sampling valve and fill the sampling bottle three fourths from the top Do not fill the bottle
108. ure 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 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 102204835 Cooling System Coolant ELC Change SMCS Code 1395 044 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 maintenanc
109. ve 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 102055282 Lift Cylinder Yoke Bearings Lubricate SMCS Code 5102 086 BD Illustration 257 g01053980 1 Lift cylinder yoke 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 MPGM grease to the fittings 102106227 Oil Filter Inspect SMCS Code 1318 507 3067 507 5068 507 Inspect a Used Filter for Debris Illustration 258 g00100013 The element is shown with debris SEBU7764 10 179 Maintenance Section Power Train Breather Clean Use a filter cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can indicate a possible failure If metals are found in the filter element a magnet can be used to differentiate between ferrous metals and nonferrous metals Ferrous metals can indicate wear on steel parts an
110. witch Stop the engine Illustration 264 g01229675 High speed oil change transmission 1 Open the left engine compartment The machine may be equipped for a high 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 182 Maintenance Section Power Train Oil Change SEBU7764 10 Illustration 265 g01181288 2 If the machine is not equipped with the high speed oil change system 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 r Dee ep ee ene os PL os Illustration 266 g01181367 4 Remove the access cover for the transmission drain plug Illustration 267 g02161317 5 Remove the plug from th

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