Operacion y Mant de D6N Track-Type Tractor - A4m1 A5m2 PDF

SAFETY.CAT.
COM™
D6N TRACK-TYPE
TRACTOR
Maintenance Intervals
Excerpted from Operation & Maintenance Manual (SEBU8408-04)
® ®
© 2009 Caterpillar
All Rights Reserved
SEBU8408-04 115
Maintenance Section
Maintenance Interval Schedule
i03620028 Every 10 Service Hours or Daily

Maintenance Interval Schedule Backup Alarm - Test ............................................. 117
Brakes, Indicators and Gauges - Test .................. 118
SMCS Code: 7000 Cab Filter (Fresh Air) - Clean/Inspect/Replace ... 120
Cooling System Level - Check ............................ 125
Ensure that all safety information, warnings and Engine Oil Level - Check .................................... 129
instructions are read and understood before any Fuel System Primary Filter/Water Separator -
operation or any maintenance procedures are Drain ................................................................. 139
performed. Fuel Tank Water and Sediment - Drain ............... 143
Hydraulic System Oil Level - Check ................... 149
The user is responsible for the performance of Seat Belt - Inspect .............................................. 154
maintenance, including all adjustments, the use of Transmission Oil Level - Check .......................... 159
proper lubricants, fluids, filters, and the replacement Winch Fairlead Rollers - Lubricate ...................... 162
of components due to normal wear and aging. Failure
to adhere to proper maintenance intervals and Every 50 Service Hours or Weekly
procedures may result in diminished performance of
the product and/or accelerated wear of components. Cab Filter (Recirculation) - Clean/Inspect/
Replace ............................................................. 120
Use mileage, fuel consumption, service hours, or Equalizer Bar Center Pin - Lubricate .................. 132
calendar time, WHICH EVER OCCURS FIRST, Power Angling Tilt Pins-Lubricate ....................... 151
in order to determine the maintenance intervals. Ripper Linkage and Cylinder Bearings -
Products that operate in severe operating conditions Lubricate ........................................................... 153
may require more frequent maintenance.
Initial 250 Service Hours
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be Engine Oil and Filter - Change ........................... 131
performed.
Every 250 Service Hours
Note: If Cat HYDO Advanced 10 hydraulic oil is
Engine Oil Sample - Obtain ................................ 130
used, the hydraulic oil change interval will change.
The normal interval of 2000 hours is extended to
3000 hours. S·O·S services may extend the oil
Every 250 Service Hours or Monthly
change even longer. Consult your Caterpillar dealer Belt - Inspect/Replace .......................................... 117
for details. Equalizer Bar Pins - Lubricate ............................ 133
Final Drive Oil Level - Check .............................. 134
When Required Pivot Shaft Oil Level - Check .............................. 151
Track - Check/Adjust ........................................... 155
Cutting Edges and End Bits - Inspect/Replace ... 126
Winch Oil Level - Check ..................................... 163
Engine Air Filter Primary Element - Clean/
Replace ............................................................. 126
Engine Air Filter Secondary Element - Replace .. 128 Initial 500 Service Hours
Engine Air Precleaner - Clean ............................ 129 Engine Valve Lash - Check/Adjust ...................... 132
Ether Starting Aid Cylinder - Replace ................. 133
Front Idler Position - Check ................................ 135 Initial 500 Hours (for New Systems, Refilled
Fuel System - Prime ........................................... 136
Systems, and Converted Systems)
Fuel System Primary Filter (Water Separator) -
Replace ............................................................. 137 Cooling System Coolant Sample (Level 2) -
Fuel System Secondary Filter - Replace ............ 139 Obtain ............................................................... 123
Fuel System Third Filter - Replace ..................... 141
Fuses and Circuit Breakers - Replace/Reset ...... 143 Every 500 Service Hours
Oil Filter - Inspect ................................................ 150
Radiator Core - Clean ......................................... 152 Cooling System Coolant Sample (Level 1) -
Radiator Pressure Cap - Clean/Replace ............ 152 Obtain ............................................................... 121
Ripper Tip - Inspect/Replace .............................. 153 Engine Air Filter Primary Element - Clean/
Transmission Magnetic Screen - Clean .............. 157 Replace ............................................................. 126
Winch Cable - Inspect ......................................... 161 Engine Air Precleaner - Clean ............................ 129
Winch Cable - Replace ....................................... 161 Final Drive Oil Sample - Obtain .......................... 135
Window Washer Reservoir - Fill .......................... 164 Fuel System Primary Filter (Water Separator) -
Window Wipers - Inspect/Replace ...................... 164 Replace ............................................................. 137
Windows - Clean ................................................. 164 Fuel System Secondary Filter - Replace ............ 139
Fuel System Third Filter - Replace ..................... 141
116 SEBU8408-04
Maintenance Section
Maintenance Interval Schedule
Hydraulic System Oil Sample - Obtain ............... 150 Every 12 000 Service Hours or 6 Years
Transmission System Oil Sample - Obtain ......... 160
Winch Oil Sample - Obtain ................................. 163 Cooling System Extended Life Coolant -
Change ............................................................. 123
Every 500 Service Hours or 3 Months
Engine Oil and Filter - Change ........................... 131
Fuel Tank Cap Filter and Strainer -
Replace/Clean .................................................. 142
Hydraulic System Oil Filter - Replace ................. 148
Recoil Spring Compartment Oil Level - Check ... 153
Steering Charge Filter - Replace ........................ 155
Every 500 Service Hours or 1 Year

Winch Drum Bearing - Lubricate ......................... 162
Every 1000 Service Hours

Engine Valve Lash - Check/Adjust ...................... 132
Every 1000 Service Hours or 6 Months

Battery - Inspect ................................................... 117
Rollover Protective Structure (ROPS) - Inspect .. 154
Transmission Oil - Change ................................. 158
Transmission Oil Filter - Replace ........................ 158
Every 2000 Service Hours or 1 Year

Final Drive Oil - Change ..................................... 134
Hydraulic System Oil - Change ........................... 146
Track Roller Frame - Inspect .............................. 157
Winch Oil - Change ............................................. 162
Winch Vent Plug - Clean ..................................... 164
Every Year
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 123
Every 2 Years
Engine Air Filter Primary Element - Clean/
Replace ............................................................. 126
Engine Air Filter Secondary Element - Replace .. 128
Every 3000 Service Hours or 2 Years

Cooling System Water Temperature Regulator -
Replace ............................................................. 125
Every 3 Years After Date of Installation or

Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 154
Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .. 121
SEBU8408-04 117
Maintenance Section
Backup Alarm - Test
i02959862 The nonadjustable backup alarm is set at the

appropriate sound level when the machine is shipped
Backup Alarm - Test from the factory.
SMCS Code: 7406-081
i01989120
Turn the engine start switch to the ON position in
order to perform the test. Battery - Inspect
SMCS Code: 1401-040
Tighten the battery retainers on all batteries at every

1000 hour interval.
1. Open the battery access cover.
2. Clean the top of the batteries with a clean

cloth. Keep the terminals clean and coated with
petroleum jelly. Install the terminal covers after
you coat the terminals.
3. Close the battery access cover.
g01477893
Illustration 150
i02386872
Apply the service brakes. Disengage the parking Belt - Inspect/Replace

brake switch. Move the transmission control lever to
the REVERSE position. SMCS Code: 1357-040; 1357-510; 1397-040;
1397-510
The backup alarm should sound immediately. The
alarm alerts the people behind the machine that the
machine is backing up. The backup alarm should Inspect
continue to sound until the transmission control
lever is moved to the NEUTRAL position or to the 1. Park the machine on level ground. Move the
FORWARD position. transmission control to the NEUTRAL position and
engage the parking brake. Shut off the engine.
2. Open the engine enclosure.
g01061657
Illustration 151
The backup alarm is on the rear of the machine.

118 SEBU8408-04
Maintenance Section
Brakes, Indicators and Gauges - Test
2. Park the machine on level ground. Move the

transmission control to the NEUTRAL position and
engage the parking brake. Shut off the engine.
3. Open the engine enclosure.
4. Turn the battery disconnect switch to the OFF

position.
5. Remove the three bolts and the two nuts in order

to remove belt guard (7), if necessary.
6. Release the tension on serpentine belt (1). Insert

a 12.7 mm (0.50 inch) ratchet into the square hole
in the belt tightener (2) and pry the belt tightener
in a counterclockwise direction.
7. Remove the belt from the pulleys. Feed the belt

over the fan.
8. Install the new belt around the pulleys.

g01191078
Illustration 152
Air conditioning
9. To achieve the correct belt tension, allow the belt
tightener (4) to return to the natural position with
(1) Serpentine belt
(2) Fan drive pulley
the belt in place. Recheck the belt adjustment.
(3) Idler
(4) Belt tensioner 10. Install the belt guard.
(5) Compressor
(6) Alternator 11. Turn the battery disconnect switch to the ON
(7) Belt guard (edge)
(8) Idler position.
3. Inspect the condition of serpentine belt (1). 12. Close the engine enclosure.
The belt deflection should not be more than
14 to 20 mm (.56 to .81 inch) under 110 N (25 lb) i02959877
of force. Measure the deflection between idler (3)
and fan drive (2) or between fan drive (2) and idler Brakes, Indicators and Gauges
(7). Use a 144-0235 Belt Tension Gauge in order
to measure the tension. - Test
Note: If a new belt is installed, recheck the belt SMCS Code: 4100-081; 7000-081; 7450-081
adjustment after 30 minutes of operation. The
deflection of the serpentine belt has the same limit Check the operation of the Caterpillar Monitoring
with an alternator only. System. Observe the self test when you start the
engine.
Note: This machine is equipped with one belt
tensioner (4). The belt tensioner automatically adjusts The system performs an automatic self test when
the belt to the correct position. you turn the engine start switch to the ON position.
4. Close the engine enclosure. The self test verifies that the monitoring panel and
the display modules are operating properly.
Replace The internal circuits, the indicators, and the gauges

are automatically checked.
1. Replace the belt if any of the following conditions
exist:
• excessive cracking
• excessive wear
• excessive damage
SEBU8408-04 119
Maintenance Section
Brakes, Indicators and Gauges - Test
Turn on all of the machine lights. Check for proper

operation. Sound the forward horn.
Move the machine forward and test the service

brakes.
Braking System (Test)
If the machine moves during the test, reduce the

engine speed immediately, and engage the park-
ing brake.
If the machine moved while testing the brakes,

consult your Caterpillar dealer for brake inspec-
tion and repair. Damaged brakes must be repaired
before returning the machine to operation.
g01477945 Note: The machine can drive through the brakes

Illustration 153
in first gear.
The operator must observe whether gauges (1), Make sure that the area around the machine is clear
indicators (2), and displays (3) are operating properly. of personnel and clear of obstacles.
The self test lasts for approximately three seconds.
Test the brakes on a dry, level surface.
During the self test, all alert indicators flash.
Fasten the seat belt before you test the brakes.
The digital display shows the following readouts:
• All indicators of units (Deg C, kPa, rpm, and liters)

• “X10” 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.
• The gear/direction readout shows “* *”. Illustration 154

g01195752
• The speed readout shows “188”, “MPH”, and 1. Start the engine.
“km/h”.
2. Raise all attachments.
• The action light stays illuminated.
3. Depress the brake pedal.
• The action alarm sounds once.
4. Release the parking brake.
The monitoring panel is then in the normal operating
mode. 5. While the brake pedal is depressed, move the
directional control to the SECOND SPEED
If the above tests are not correctly completed, the FORWARD position.
system will not function in the normal operating
mode. Consult your Caterpillar dealer for an electrical 6. Gradually increase the engine speed to full load
system check. Any repairs must be made before you speed. The machine should not move.
start the engine.
120 SEBU8408-04
Maintenance Section
Cab Filter (Fresh Air) - Clean/Inspect/Replace
7. Move the directional control to the NEUTRAL 1. Open the filter cover and remove the filter
position. elements. The filter cover is in front of the cab.
8. Reduce the engine speed to LOW IDLE. Engage 2. Clean the filter elements with low pressure air.
the parking brake. Lower all attachments to the
ground. Apply a slight down pressure. Stop the Note: Do not use air pressure higher than 200 kPa
engine. (30 psi). Direct the air from the clean side to the dirty
side. Do not wash the filter elements.
9. Make any necessary repairs before you operate
the machine. 3. Look through the filter toward a bright light. Inspect
the filter elements and the gaskets for damage.
NOTICE Replace damaged filters or gaskets.
If the machine moved while testing the brakes, contact
your Caterpillar dealer. Have the dealer inspect and, 4. Install the filter elements. Close the filter cover.
if necessary, repair the service brake before returning
the machine to operation. i02387641
Cab Filter (Recirculation) -

i02567762
Clean/Inspect/Replace
Cab Filter (Fresh Air) -
SMCS Code: 7342-040; 7342-070; 7342-510
Clean/Inspect/Replace
Note: Inspect the filters and clean the filters more
SMCS Code: 7342-040; 7342-070-FI; 7342-070; often in dusty conditions.
7342-510-FI; 7342-510
Note: Inspect the filters and clean the filters more

often in dusty conditions.
g01191944
Illustration 157
Front view of right side
g01321249 1. Turn the cover retaining knob and open the filter
Illustration 155 cover. Remove the filter element. The filter cover
is just inside the cab door at the bottom of the cab.
Note: Remove both of the recirculation filters from

the cab.
2. Clean the filter elements with low pressure air.
Note: Do not use air pressure higher than 200 kPa

(30 psi). Direct the air from the clean side to the dirty
side. Do not wash the filter elements.
3. Look through the filter toward a bright light. Inspect

the filter elements and the gaskets for damage.
Replace damaged filters or gaskets.
g01191841
Illustration 156
4. Install the filter elements. Close the filter cover.
SEBU8408-04 121
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
i03646300
Cooling System Coolant

Extender (ELC) - Add
SMCS Code: 1395-538
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01321274
Illustration 158
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies 1. The filler cap is located under access door
suitable to collect and contain fluids on Caterpillar (1) on the top, left side of the radiator guard.
products. Slowly loosen the filler cap in order to relieve the
pressure. Remove the cap.
Dispose of all fluids according to local regulations and
mandates. 2. Add ELC. Drain some coolant from the radiator
into a suitable container in order to allow space
Table 21 for the extra ELC.
RECOMMENDED AMOUNT OF EXTENDER BY
COOLING SYSTEM CAPACITY Note: Always discard drained fluids according to
local regulations.
Recommended Amount
Cooling System Capacity
of Extender 3. Start the engine. Run the engine without the filler
22 to 30 L (6 to 8 US gal) 0.57 L (0.60 qt) cap until the thermostat opens and the coolant
level stabilizes. Check for leaks.
30 to 38 L (8 to 10 US gal) 0.71 L (0.75 qt)
38 to 49 L (10 to 13 US gal) 0.95 L (1 qt) 4. Check the coolant level. If necessary, add
premixed coolant in order to correct the coolant
49 to 64 L (13 to 17 US gal) 1.18 L (1.25 qt) level. Maintain the coolant level at the bottom of
65 to 83 L (17 to 22 US gal) 1.60 L (54 oz) the filler tube.
5. Inspect the filler cap gasket. Replace the filler cap

When a Caterpillar Extended Life Coolant (ELC) if the gasket is damaged.
is used, an extender must be added to the cooling
system. See the Operation and Maintenance 6. Install the filler cap.
Manual, “Maintenance Interval Schedule” for the
proper service interval. The amount of extender is
determined by the cooling system capacity. i02960100
For additional information about adding an extender, Cooling System Coolant

see Special Publication, SEBU6250, “Caterpillar Sample (Level 1) - Obtain
Machine Fluids Recommendations” or consult your
Caterpillar dealer. SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Note: It is not necessary to obtain a Coolant

Sample (Level 1) if the cooling system is filled
with Cat ELC (Extended Life Coolant). Cooling
systems that are filled with Cat ELC should have
a Coolant Sample (Level 2) that is obtained at
the recommended interval that is stated in the
Maintenance Interval Schedule.
122 SEBU8408-04
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
Note: Obtain a Coolant Sample (Level 1) if the 2. Remove the cap to the S·O·S sampling valve that
cooling system is filled with any other coolant is located toward the front of the engine behind
instead of Cat ELC. This includes the following the bottom end of the secondary fuel filter.
types of coolants.
Note: Always discard drained fluids according to
• Commercial long life coolants that meet the local regulations.
Caterpillar Engine Coolant Specification -1
(Caterpillar “EC−1”) Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order
• Cat Diesel Engine Antifreeze/Coolant (DEAC) to receive the full effect of S·O·S analysis, you
must establish a consistent trend of data. In order
• Commercial heavy-duty antifreeze/coolant to establish a pertinent history of data, perform
consistent samplings that are evenly spaced.
NOTICE Supplies for collecting samples can be obtained from
Always use a designated pump for oil sampling, and your Caterpillar dealer.
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may Use the following guidelines for proper sampling of
contaminate the samples that are being drawn. This the coolant:
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both • Complete the information on the label for the
dealers and customers. sampling bottle before you begin to take the
samples.
Note: Level 1 results may indicate a need for • Keep the unused sampling bottles stored in plastic
Level 2 Analysis. bags.
• Obtain coolant samples directly from the coolant

sample port. You should not obtain the samples
from any other location.
• Keep the lids on empty sampling bottles until you

are ready to collect the sample.
• Place the sample in the mailing tube immediately

after obtaining the sample in order to avoid
contamination.
• Never collect samples from expansion bottles.
g01478193 • Never collect samples from the drain for a system.

Illustration 159
3. Replace the cap to the S·O·S sampling valve.
4. Close the left engine access door.
Submit the sample for Level 1 analysis.
For additional information about coolant analysis, see

Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” or consult your Caterpillar
dealer.
g01478217
Illustration 160
1. Open the left engine access door.

SEBU8408-04 123
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
i02960132 Use the following guidelines for proper sampling of

the coolant:
Cooling System Coolant
Sample (Level 2) - Obtain • Complete the information on the label for the
sampling bottle before you begin to take the
SMCS Code: 1350-008; 1395-008; 1395-554; 7542 samples.
NOTICE
• Keep the unused sampling bottles stored in plastic
bags.
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
• Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
contaminate the samples that are being drawn. This from any other location.
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
• Keep the lids on empty sampling bottles until you
are ready to collect the sample.
• Place the sample in the mailing tube 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.
3. Replace the cap to the S·O·S sampling valve.
4. Close radiator access door (1).
Submit the sample for Level 2 analysis.

g01478193
Illustration 161 For additional information about coolant analysis, see
Special Publication, SEBU6250, “Caterpillar Machine
1. Open the left engine access door. Fluids Recommendations” or consult your Caterpillar
dealer.
i02567780
Cooling System Extended Life

Coolant - Change
SMCS Code: 1350-044; 1395-044
NOTICE
Illustration 162
g01478217 collect the fluid with suitable containers before open-
2. Remove the cap to the S·O·S sampling valve that nent containing fluids.
is located behind the bottom end of the secondary
fuel filter toward the front of the engine. Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
Note: Always discard drained fluids according to suitable to collect and contain fluids on Caterpillar
local regulations. products.
Obtain the sample of the coolant as close as possible Dispose of all fluids according to local regulations and
to the recommended sampling interval. Supplies mandates.
for collecting samples can be obtained from your
Caterpillar dealer.
124 SEBU8408-04
Maintenance Section
Cooling System Extended Life Coolant - Change
Reference: For information about adding an

extender to your cooling system, refer to Special
Publication, SEBU6250, “Caterpillar Machine Fluids
Recommendations”, “Extended Life Coolant (ELC)
Cooling System Maintenance” or consult your
Caterpillar dealer.
Flushing the ELC from the Cooling

System
Some engines use Extended Life Coolant (ELC).
If an ELC was previously used, flush the cooling
system with clean water. No other cleaning agents
are required.
Flushing a Standard Coolant from

the Cooling System
If you change to an ELC from another type of
coolant, use a Caterpillar cleaning agent to flush the Illustration 164
g01286197
cooling system. After you drain the cooling system,
thoroughly flush the cooling system with clean water. 2. The drain valve is accessible from the underside
All of the cleaning agent must be removed from of the machine. Open the drain valve. Allow the
the cooling system. coolant to drain into a suitable container.
Draining and Flushing Procedure 3. Close the drain valve. If you drained a standard
coolant from the system proceed to Step 4. If you
Drain the coolant whenever the coolant is dirty or drained ELC from the system proceed to Step 6.
whenever foaming is observed.
4. Fill the system with a solution which consists
The radiator cap is positioned under the access door of clean water and of cooling system cleaner.
in the top of the hood. The concentration of the cooling system cleaner
should be 6 to 10 percent.
1. Slowly loosen the radiator cap in order to relieve
system pressure. Remove the radiator cap. 5. Start the engine. Run the engine for 90 minutes.
Stop the engine. Drain the cleaning solution into a
suitable container.
6. While the engine is stopped, flush the system with

water. Flush the system until the draining water
is clear.
7. Close the drain valve.
8. Add the coolant solution.
Reference: For coolant information, refer to

Special Publication, SEBD0518, “Know Your
Cooling System” and Operation and Maintenance
Manual, “Capacities (Refill)”.
9. Start the engine. Run the engine without the

radiator cap until the thermostat opens and the
coolant level stabilizes.
10. Check the coolant level. Make necessary

g01286195 adjustments to the coolant level.
Illustration 163
SEBU8408-04 125
Maintenance Section
Cooling System Level - Check
11. If the gasket is damaged, replace the radiator A water temperature regulator that fails in the open
cap. Install the radiator cap. position will cause the engine operating temperature
to be too low during partial load operation. Low
12. Stop the engine. engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
i03646191
in an accelerated wear of the piston rings and wear
Cooling System Level - Check of the cylinder liner.
SMCS Code: 1353-535-FLV; 1395-535-FLV NOTICE

Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe
engine damage.
Caterpillar engines incorporate a shunt design cooling

system and require operating the engine with a water
temperature regulator installed.
If the water temperature regulator is installed incor-

rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
ulator is installed in the original position. Ensure that
the water temperature regulator vent hole is open.
g01286221
Do not use liquid gasket material on the gasket or
Illustration 165 cylinder head surface.

Refer to the Service Manual for the replacement
2. Observe the sight glass in order to verify the level procedure of the water temperature regulator, or
of the coolant. If the coolant level covers the entire consult your Caterpillar dealer.
sight glass, the coolant level is acceptable. If
the coolant level is visible in the sight glass, the Note: If only the water temperature regulators are
coolant level is low. Add coolant in order to fill the replaced, drain the coolant from the cooling system to
cooling system. a level that is below the water temperature regulator
housing.
i02395314
Cooling System Water

Temperature Regulator -
Replace
SMCS Code: 1355-510
Replace the water temperature regulator before

the water temperature regulator fails. This is a
recommended preventive maintenance practice.
Replacing the water temperature regulator reduces
the chances for unscheduled downtime.
A water temperature regulator that fails in a

partially opened position can cause overheating or
overcooling of the engine.
A water temperature regulator that fails in the closed

position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
head or piston seizure problems.
126 SEBU8408-04
Maintenance Section
Cutting Edges and End Bits - Inspect/Replace
i02388261 10. After you operate the machine for a few hours,
check all bolts for the proper torque.
Cutting Edges and End Bits -
Inspect/Replace i02960141
SMCS Code: 6801-040; 6801-510; 6804-040; Engine Air Filter Primary

6804-510
Element - Clean/Replace
SMCS Code: 1051-070; 1051-510-PY; 1054-070-PY;
1054-510-PY
NOTICE
Caterpillar recommends certified air filter cleaning ser-
vices that are available at Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.
Observe the following guidelines if you attempt to

clean the filter element:
Do not tap or strike the filter element in order to re-

move dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove

the dust from the filter element. Air pressure must not
Illustration 166
g01097854 exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
1. Raise the bulldozer blade and block up the element. Take extreme care in order to avoid damage
bulldozer blade. When you remove the cutting to the pleats.
edges and the end bits, maintain the bulldozer
blade at a minimum height. Do not use air filters with damaged pleats, gaskets, or
seals. Dirt entering the engine will cause damage to
2. Remove the bolts. engine components.
3. Remove the cutting edge and the end bits.
4. Thoroughly clean all contact surfaces.
5. Inspect the opposite side of the cutting edge. If the

opposite side of the cutting edge is not worn, turn
the opposite side of the cutting edge downward
and install the cutting edge.
6. If both sides of the cutting edge are worn, install a

new cutting edge.
7. Repeat Steps 5 and 6 for the end bits.

g01478193
8. Install all bolts and tighten the bolts to the specified Illustration 167
torque.
1. Open the engine access door on the left side of
Reference: For more information, refer the machine.
to Specifications, SENR3130, “Torque
Specifications”.
9. Raise the bulldozer blade and remove the

blocking. Lower the bulldozer blade to the ground.
SEBU8408-04 127
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
7. Start the engine. If the yellow piston in the filter

element indicator moves into the red zone,
check the indicator for damage. Replace the filter
element indicator if damage is present.
Cleaning Primary Air Filter

Elements
The primary air filter element can be used up to six
times if the element is properly cleaned and properly
inspected. When the primary air filter element is
cleaned, check for rips or tears in the filter material.
The primary air filter element should be replaced at
g01192366
least one time per two year period. This replacement
Illustration 168 should be performed regardless of the number of
cleanings.
2. Loosen the four cover latches and remove the air
cleaner cover.
NOTICE
Note: The latches for the air cleaner housing may Do not clean the air filter elements by bumping or tap-
snap open when you release the latches. ping. This could damage the seals. Do not use ele-
ments with damaged pleats, gaskets, or seals. Dam-
3. Remove the primary filter element from the air aged elements will allow dirt to pass through. Engine
cleaner housing. In order to remove the engine air damage could result.
filter primary element, pull the element outward.
While you pull the element outward, rock the Visually inspect the primary air filter elements before
element. cleaning. Inspect the air filter elements for damage
to the seal, the gaskets, and the outer cover. Discard
NOTICE any damaged air filter elements.
Do not use a filter if the media, the gaskets or the seals
are damaged. Pressurized air is the best method to clean primary
air filter elements.
4. Install a clean primary filter element over the
engine air filter secondary element. Apply firm Pressurized Air
pressure to the end of the primary element as
you gently rock the filter element. This seats the
primary element.
5. Clean the cover and install the cover.
6. Close the access door.
g01205120
Illustration 170
Direction of air flow
Pressurized air can be used to clean primary air filter

elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum
Illustration 169
g01192466 pressure of 207 kPa (30 psi).
The filter element indicator is located on the air cleaner group in
the left engine compartment.
128 SEBU8408-04
Maintenance Section
Engine Air Filter Secondary Element - Replace
Note: When the primary air filter element is cleaned, i02960151

always blow the air from the clean side in order to
force dirt particles toward the dirty side. This helps Engine Air Filter Secondary
prevent damage to the paper pleats. Element - Replace
Do not touch the tip of the air gun to the primary air SMCS Code: 1051-510-SE; 1054-510-SE
filter element. Dirt could be forced further into the
pleats.
NOTICE
Before you reuse the primary air filter element, check Always replace the secondary element. Do not at-
for any damage to the seals, the gaskets, and the tempt to reuse it by cleaning. Engine damage could
bellows. Discard any damaged air filter elements. result.
Inspecting the Primary Air Filter Note: Replace the secondary filter element when
you service the primary element for the third time.
Elements If a clean primary element has been installed
and the filter element indicator still enters the red
Do not use a primary air filter element that has any zone, replace the secondary filter element. Also
tears and/or holes in the filter material. Do not use if the exhaust smoke remains black and a clean
a primary air filter element with damaged pleats, primary filter element has been installed, replace the
gaskets or seals. Discard damaged primary air filter secondary filter element.
elements.
Storing Primary Air Filter Elements

If a primary air filter element that passes inspection
will not be used, the primary air filter element can
be stored for future use.
g01478193
Illustration 172
2. Remove the housing cover to the precleaner body

assembly.
g00281694
Illustration 171
Do not use paint, a waterproof cover, or plastic as a

protective covering for storage. An air flow restriction
may result. To protect against dirt and damage, wrap
the primary air filter elements in Volatile Corrosion
Inhibited (VCI) paper.
Place the primary air filter element into a box for

storage. For identification, mark the outside of the
box and mark the primary air filter element. Include
the following information:
• Date of cleaning g01192559

Illustration 173
• Number of cleanings Secondary air cleaner element
Store the box in a dry location.

SEBU8408-04 129
Maintenance Section
Engine Air Precleaner - Clean
3. Remove the secondary element. The secondary 3. Inspect the engine air precleaner for dirt and for
element is on the end of the air cleaner group trash.
toward the cab.
4. Unscrew T-bolt (1) in order to remove the
4. Cover the air inlet opening. Clean the inside of integrated precleaner body (2) completely.
the air cleaner housing.
5. Use pressurized air to clean the tubes. Put the
5. Inspect the gasket between the air inlet and the tubes on a flat surface. Direct the pressurized air
housing. If the gasket is damaged, replace the into the tubes from the top. This loosens up the
element. dirt.
6. Uncover the air inlet opening. Install a new a. Loosen hard deposits of dust on the precleaner
secondary element. body by soaking in an appropriate cleaning
agent. Then, wash the precleaner body with
7. Install the air cleaner housing cover. a spray of water.
8. Close the engine access door. b. Blow dry the precleaner body completely.
6. Install precleaner body (2) into the engine air

i02960166
precleaner. Latch the precleaner body in place.
Engine Air Precleaner - Clean 7. Install T-bolt (1). Hand tighten the T-bolt only.
SMCS Code: 1050-070
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.
i02960180
Engine Oil Level - Check

SMCS Code: 1302-535-FLV; 1326-535-FLV
g01478193
Illustration 174
Hot oil and components can cause personal in-
1. Open the left engine access cover. jury.
2. If the machine is equipped with a rain cap, remove Do not allow hot oil or components to contact
the cap. skin.
NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
g01205111
Illustration 175
130 SEBU8408-04
Maintenance Section
Engine Oil Sample - Obtain
i02960199
Engine Oil Sample - Obtain

SMCS Code: 1348-554-SM; 1348; 7542

jury.
Do not allow hot oil or components to contact

skin.
g01478193
Illustration 176
1. Open the access cover that is on the left side of

the machine.
g01478193
Illustration 178
1. Open the engine compartment cover on left side of

the machine. Refer to Operation and Maintenance
Manual, “General Hazard Information” for
g01478261
Illustration 177 information that pertains to containing fluid
spillage.
2. Check the dipstick (2) while the engine is stopped.
Maintain the oil level between the “LOW” mark
and the “FULL” mark.
Note: When you operate the machine on severe

slopes, the oil level in the engine crankcase must be
at the “FULL” mark on the dipstick.
3. Remove oil filler cap (1). If necessary, add oil.
4. Clean the oil filler cap and install the oil filler cap.
5. Close the access cover.
g01478285
Illustration 179
2. Obtain the regularly scheduled oil sample.
a. Use the oil sampling valve (1). Refer to Special

Publication, PEHP6001, “How To Take A Good
Oil Sample”.
SEBU8408-04 131
Maintenance Section
Engine Oil and Filter - Change
Reference: See Special Publication, SEBU6250, Engine Oil and Filter (Change)
“Caterpillar Fluids and Recommendations”, “S·O·S
Oil Analysis” and “Sampling Interval and Location of
Sampling Valve” for more information.
i02960231
Engine Oil and Filter - Change

SMCS Code: 1308; 1318-510

jury.

skin.
NOTICE
A 500 hour engine oil change interval is available, pro-
g01286269
vided that the operating conditions and recommend- Illustration 180
ed multigrade oil types are met. When these require-
ments are not met, shorten the oil change interval 2. The crankcase drain valve is accessible from the
to 250 hours, or use an S·O·S Services oil sampling underside of the machine. Open the crankcase
and analysis program to determine an acceptable oil drain valve. Allow the oil to drain into a suitable
change interval. container.
If you select an interval for oil and filter change that is

too long, you may damage the engine.
Obtain Engine Oil Sample

1. Open the engine compartment cover on the left
side of the machine.
a. Obtain the regularly scheduled oil sample, if

necessary.
See Operation and Maintenance Manual, “Engine Oil

Sample - Obtain” for the proper procedure. g01478312
Illustration 181
3. Remove the engine oil filter element (1) and

discard the engine oil filter element properly. Make
sure that all of the old filter seal is removed from
the filter base.
4. Apply a thin coat of clean engine oil to the seal

on the new filter. Install the new engine oil filter
element by hand.
Note: Instructions for the installation of the filters are

printed on the side of each Caterpillar spin-on filter.
For non-Caterpillar filters, refer to the installation
instructions that are provided by the supplier of the
filter.
132 SEBU8408-04
Maintenance Section
Engine Valve Lash - Check/Adjust
5. Tighten the filter according to the instructions

that are printed on the filter. Use the index marks
as a guide. For non-Caterpillar filters, use the
Ensure that the engine can not be started while
instructions that are provided with the filter.
this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
Note: You may need to use a Caterpillar strap
to turn the flywheel.
wrench, or another suitable tool, in order to turn
the filter to the amount that is required for final
Hot engine components can cause burns. Allow
installation. Make sure that the installation tool does
additional time for the engine to cool before mea-
not damage the filter.
suring/adjusting valve lash clearance.
6. Close the crankcase drain valve. Replace the
crankcase guard. NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
ment procedure.
Operation of Caterpillar engines with improper valve

adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life.
Note: Any air lines that are disconnected during a

valve lash adjustment must be plugged in order to
protect the engine. Prevent the entry of airborne dirt,
debris and abrasive particles. Keep all parts clean
g01478315
Illustration 182 from contamination. Contaminants may cause rapid
wear. This shortens the component life.
7. Remove the oil filler cap (2). Fill the crankcase
with new oil. See Operation and Maintenance
i02568284
Manual, “ Capacities (Refill)”. Clean the oil filler
cap and install the oil filler cap. Equalizer Bar Center Pin -
8. Always measure the oil level with dipstick (3) in Lubricate
order to ensure that the correct amount of oil was
added. SMCS Code: 7206-086-PN; 7207-086-PN
9. On the dipstick, maintain the oil level between the NOTICE

“ADD” mark and the “FULL” mark. Apply lubricant to the fittings with a hand operated
grease gun only. Use of pressure operated lubricating
10. Close the engine compartment cover on the left equipment damages the seals.
i03363188
Engine Valve Lash -

Check/Adjust
SMCS Code: 1102-025; 1102
This maintenance is recommended by Caterpillar

as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.
g01321324
Illustration 183
SEBU8408-04 133
Maintenance Section
Equalizer Bar Pins - Lubricate
g01192649 g01192660
Illustration 184 Illustration 186
Front view of right side
1. Remove the plug.
Lubricate the equalizer bar center pin through the
remote fitting. The fitting is located on the right side 2. Lubricate the fitting.
of the machine close to the engine compartment.
3. Install the plug.
i02960465 4. Lubricate the end fittings.

Equalizer Bar Pins - Lubricate
i02411020
SMCS Code: 7206-086-PN; 7207-086-PN
Ether Starting Aid Cylinder -
NOTICE Replace
Apply lubricant to the fittings with a hand operated
grease gun only. Use of pressure operated lubricating SMCS Code: 1456-510-CD
equipment damages the seals.
1. Open the right engine access door.
g01478499
Illustration 185 g01205079
Illustration 187
2. The ether starting aid cylinder is mounted on the

right side of the engine compartment by the cab
supports.
3. Loosen the cylinder retaining clamp. Unscrew the

empty ether starting aid cylinder and remove the
empty ether starting aid cylinder.
4. Remove the used gasket. Install the new gasket

that is provided with each new ether starting aid
cylinder.
134 SEBU8408-04
Maintenance Section
Final Drive Oil - Change
5. Install the new ether starting aid cylinder. Tighten 7. Inspect the condition of the oil filler plug. Replace
the ether starting aid cylinder by hand. Tighten the the oil filler plug if the oil filler plug is damaged.
cylinder retaining clamp securely.
8. Repeat Steps 1 through 7 in order to change the
6. Close the engine access door. oil in the other final drive.
i02389127 i02389257
Final Drive Oil - Change Final Drive Oil Level - Check

SMCS Code: 4050-535-FLV SMCS Code: 4050-535-FLV
Hot oil and components can cause personal in- Hot oil and components can cause personal in-
jury. jury.
Do not allow hot oil or components to contact Do not allow hot oil or components to contact
skin. skin.
g01141777 g01141777
1. Position one final drive so that oil level mark (1) is 1. Position one final drive so that oil level mark (1) is
horizontal. Drain plug (3) should face downward. horizontal. Drain plug (3) should face downward.
2. Remove drain plug (3). Allow the oil to drain into a 2. Remove oil filler plug (2).
suitable container.
3. The oil level should be at the bottom of the filler
3. Inspect the drain plug seal. Replace the drain plug plug opening. Add oil, if necessary.
seal if the drain plug seal is damaged.
4. Install oil filler plug (2).
4. Clean the drain plug and install the drain plug.
5. Repeat Steps 1 through 4 in order to check the oil
5. Remove oil filler plug (2). level in the other final drive.
6. Fill the final drive with oil to the bottom of the filler
plug opening. See Operation and Maintenance
Manual, “Refill Capacities”.
SEBU8408-04 135
Maintenance Section
Final Drive Oil Sample - Obtain
i02389265
Final Drive Oil Sample - Obtain

SMCS Code: 3258-008; 4011-008; 4050-008;
4050-SM; 4070-008; 4070-554-SM; 7542-008
Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.
NOTICE
g01179048
Illustration 190
Refer to Special Publication, NENG2500, “Caterpillar Oil sampling
suitable to collect and contain fluids on Caterpillar 1. Position one final drive so that oil level mark (1) is
products. horizontal.
Dispose of all fluids according to local regulations and 2. Remove oil filler plug (2) and obtain the oil sample
mandates. with a proper suction device. Use a 1U-7683
Suction Gun or use an equivalent pump such as
1U-5718 Vacuum Pump to take the oil sample.
Obtain the Sample and the Analysis
3. Install oil filler plug (2).
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
4. Repeat Step 1 to Step 3 in order to sample the oil
analysis at regular scheduled intervals in order
in the other final drive.
to monitor the condition and the maintenance
requirements of the final drives.
Refer to Special Publication, PEHP6001 for more
information on obtaining a good oil sample. Consult
Each oil sample should be taken when the oil is warm
your Caterpillar dealer for complete information and
and when the oil is well mixed in order to ensure that
assistance in establishing an S·O·S program for your
the sample is representative of the oil in the final
machine.
drives.
Obtain the S·O·S Sample i02563398
To avoid contamination of the oil samples, the tools Front Idler Position - Check
and the supplies that are used for obtaining oil
samples must be clean. SMCS Code: 4159
SystemOne Undercarriage
The following check is for Caterpillar SystemOne
Undercarriages that have the center tread idler.
136 SEBU8408-04
Maintenance Section
Fuel System - Prime
g01151486
Illustration 192
Adjustment shim (center tread idler)
5. For machines with the SystemOne Undercarriage,

remove one shim under each track idler block
when the wear on the link and roller system is at
Illustration 191
g01149978 50%.
Elevated undercarriage system
Consult your Caterpillar dealer for detailed
information about adjustments to the center tread
1. Park the machine on a hard, flat surface. Make idler.
sure that the bottom track is tight and that the
measured grouser lies directly below the track See Operation and Maintenance Manual, “Track
idler shaft. - Check/Adjust” for information on needed track
adjustments.
2. Measure the height (A, B) from the flat ground
surface to the grouser tip that is centered below Reference: See Operation and Maintenance
the track idler shaft. Manual, “Reference Material” for publications and
Special Instructions on removal and installation of
3. Maintain the grouser height (rise) to the following SystemOne Track, as needed.
dimensions.
a. (A) Front Idlers i02960507
Minimum – 0 mm (0 inch) Fuel System - Prime

Maximum – 20 mm (0.8 inch) SMCS Code: 1258
b. (B) Rear Idlers
Minimum – 10 mm (0.4 inch) Personal injury or death may result from failure to
adhere to the following procedures.
Maximum – 40 mm (1.6 inch)
Fuel leaked or spilled onto hot surfaces or electri-
4. Repeat Steps 1 through 3 in order to determine cal components can cause a fire.
the proper height dimension under each idler.
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.
SEBU8408-04 137
Maintenance Section
Fuel System Primary Filter (Water Separator) - Replace
i02962641
NOTICE
Fuel System Primary Filter
during performance of inspection, maintenance, test- (Water Separator) - Replace
collect the fluid with suitable containers before open- SMCS Code: 1263-510

Personal injury can result from air pressure.
suitable to collect and contain fluids on Caterpillar
Personal injury can result without following prop-
products.
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
mandates.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
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 Personal injury can result when using cleaner sol-
vents.
This machine is equipped with an electric fuel priming
pump. 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.

cal components can cause a fire.


Illustration 193
g01478616 battery when changing fuel filters.
Note: You can only use the priming pump when NOTICE
the engine start switch key is OFF. Do not pre-fill the fuel filter with fuel before you install
the fuel filter. Contaminated fuel WILL DAMAGE the
1. Move the switch for the electric fuel priming pump fuel system components.
to the ON position. Allow the pump to run for
several seconds.
NOTICE
2. Return the switch for the electric fuel priming Caterpillar STRONGLY recommends the use of
pump to the OFF position. high efficiency fuel filters. High efficiency fuel fil-
ters are designed in order to better protect diesel
3. Start the engine. If the engine does not start, engines that have higher injection pressures and
or if the engine continues to misfire or smoke, closer tolerances. Use of fuel filters that are NOT
additional priming may be necessary. The electric high efficiency fuel filters will result in shortened
fuel priming pump will only operate if the engine fuel system component life. Caterpillar high ef-
start switch key is in the OFF position. Shut off the ficiency fuel filters are the preferred filters for
engine before additional priming. Caterpillar engines.
4. Run the engine at the LOW IDLE position until the
engine runs smoothly.
138 SEBU8408-04
Maintenance Section
Fuel System Primary Filter (Water Separator) - Replace
In order to keep the engine in optimum condition, it is

important to keep the fuel free from contamination.
As fuel system contamination usually occurs during
refueling, the following points should be observed:
• Only use clean fuel of the correct grade from

a reliable source.
• Do not refuel from contaminated containers or

containers that are not suitable for fuel storage.
• Do not use contaminated equipment.

• Regularly clean the outside of the fuel filler cap
and the area around the fuel filler cap. g01483773
Illustration 194
• Only use Caterpillar approved fuel filters. The

use of Caterpillar filters is essential in order to 4. Open the drain (3). Allow the fluid to drain into
protect the fuel system. the container.
• Do not service the fuel filters ahead of the 5. Tighten the drain by hand pressure only.
suggested maintenance interval, unless you
are instructed by the monitoring system. This 6. If equipped, remove the wiring harness from the
will increase the risk of contamination in the sensor on the bottom of the glass bowl (2).
fuel system.
7. Remove the glass bowl from the filter (1).
Note: The service indicator for the fuel system will
be illuminated if the sediment bowl needs to be 8. Use a Caterpillar strap wrench in order to remove
emptied. The service indicator for the fuel system will the filter. Discard the old seals and the canister in
be illuminated if the primary fuel filter is plugged or if a safe place.
the secondary fuel filter is plugged. If the indicator is
illuminated, empty the water in the sediment bowl. If 9. Clean the glass bowl.
the indicator remains illuminated, replace the primary
fuel filter and the secondary fuel filter. Note: Before you install the fuel filter, do not
attempt to fill the fuel in the fuel filter.
Note: In order to reduce the risk of contamination in
the system, do not remove the primary fuel filter and 10. Install the new filter by hand.
the secondary fuel filters simultaneously. Perform
these operations separately. Instructions for the installation of the filter are
printed on the side of each Caterpillar spin-on
Note: After the engine has stopped, you must filter. For non-Caterpillar filters, refer to the
wait for 60 seconds in order to allow the fuel installation instructions that are provided by the
pressure to be purged from the high pressure fuel supplier of the filter.
lines before any service or repair is performed
on the engine fuel lines. 11. Install the glass bowl on the filter. Ensure that the
sensor (if equipped) is in the correct position.
the machine. The fuel filter element is located 12. If equipped, install the wiring harness to the
toward the front of the engine. sensor.
2. Turn the fuel supply valve (if equipped) to the OFF 13. Be sure to dispose of the fuel in a safe place.
position before performing this maintenance.
14. Be sure to mark the sticker for the maintenance
3. Place a suitable container under the water schedule that is attached to the third fuel filter.
separator in order to catch any fuel that might spill.
Clean up any spilled fuel. Clean the outside of the 15. Prime the fuel system. Refer to Operation and
water separator and the fuel filter. Maintenance Manual, “Fuel System - Prime” for
more information.
16. Before you start the engine, make sure that the
drain valves are completely closed. Start the
engine. Check for leaks.
SEBU8408-04 139
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
17. Close the engine access door.
Replace the Secondary Fuel Filter

Replace the secondary fuel filter immediately after
you change the primary fuel filter. Refer to Operation
and Maintenance Manual, “Fuel System Secondary
Filter - Replace”for more information.
Replace the Third Fuel Filter

Replace the third fuel filter at the same interval as the
primary fuel filter and the secondary fuel filter. Refer
to Operation and Maintenance Manual, “Fuel System g01483895
Third Filter - Replace” for more information. Illustration 195
1. Place a suitable container directly underneath the

i02962743 drain valve. The Drain is located under the primary
fuel filter/water separator.
Fuel System Primary
Filter/Water Separator - Drain 2. Open drain . Allow the fluid to drain into the
container.
SMCS Code: 1260-543; 1263-543
3. After the separator is completely drained, close
drain by hand pressure only. Dispose of the
drained fluid in a safe place.
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre- i02963340
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements. Fuel System Secondary Filter -
Clean up fuel spills immediately. Replace
SMCS Code: 1261-510-SE
NOTICE
collect the fluid with suitable containers before open- Personal injury can result from air pressure.
nent containing fluids. Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
Refer to Special Publication, NENG2500, “Caterpillar tective face shield and protective clothing.
suitable to collect and contain fluids on Caterpillar Maximum air pressure at the nozzle must be less
products. than 205 kPa (30 psi) for cleaning purposes.

mandates.
Personal injury can result when using cleaner sol-

vents.
To help prevent personal injury, follow the instruc-

er before using.
140 SEBU8408-04
Maintenance Section
Fuel System Secondary Filter - Replace
Note: The service indicator for the fuel system will

be illuminated if the sediment bowl needs to be
emptied. The service indicator for the fuel system will
be illuminated if the primary fuel filter is plugged or if
the secondary fuel filter is plugged. If the indicator is
illuminated, empty the water in the sediment bowl. If
the indicator remains illuminated, replace the primary
fuel filter and the secondary fuel filter.
Note: In order to reduce the risk of contamination
in the system, do not remove the primary fuel filter
and the secondary fuel filter simultaneously. Perform
these operations separately.
NOTICE Note: After the engine has stopped, you must

Do not pre-fill the fuel filter with fuel before you install wait for 60 seconds in order to allow the fuel
the fuel filter. Contaminated fuel WILL DAMAGE the pressure to be purged from the high pressure fuel
fuel system components. lines before any service or repair is performed
on the engine fuel lines.
NOTICE 1. Open the engine access door on the left side of

Caterpillar STRONGLY recommends the use of the machine. The secondary fuel filter is located
high efficiency fuel filters. High efficiency fuel fil- on the front of the engine on the left side.
ters are designed in order to better protect diesel
engines that have higher injection pressures and 2. Ensure that the fuel supply valve (if equipped) is in
closer tolerances. Use of fuel filters that are NOT the OFF position. Place a suitable container under
high efficiency fuel filters will result in shortened the fuel filter in order to catch any fuel that might
fuel system component life. Caterpillar high ef- spill. Clean up any spilled fuel.
ficiency fuel filters are the preferred filters for
Caterpillar engines.

important to keep the fuel free from contamination.
As fuel system contamination usually occurs during
• Only use clean fuel of the correct grade from

a reliable source.
• Do not refuel from contaminated containers or

• Do not use contaminated equipment. Illustration 196

g01484613
• Regularly clean the outside of the fuel filler cap 3. Clean the outside of the fuel filter. Use a Caterpillar
and the area around the fuel filler cap. strap wrench in order to remove the filter from the
engine and dispose of the filter in a safe place.
• Only use Caterpillar approved fuel filters. The
use of Caterpillar filters is essential in order to Note: Before you install the fuel filter, do not
protect the fuel system. attempt to fill the fuel in the fuel filter.
• Do not service the fuel filters prior to the 4. Install the new filter by hand.
suggested maintenance interval. This may
increase the risk of contamination in the fuel Instructions for the installation of the filter are
system. 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.
5. Be sure to mark the sticker for the maintenance

schedule that is attached to the third fuel filter.
SEBU8408-04 141
Maintenance Section
Fuel System Third Filter - Replace
6. Prime the fuel system. Refer to the Operation and

Maintenance Manual, “Fuel System - Prime” for NOTICE
more information. Caterpillar STRONGLY recommends the use of
high efficiency fuel filters. High efficiency fuel fil-
7. Before you start the engine, make sure that the ters are designed in order to better protect diesel
drain valves are completely closed. Start the engines that have higher injection pressures and
engine. Check for leaks. closer tolerances. Use of fuel filters that are NOT
high efficiency fuel filters will result in shortened
8. Close the engine access door. fuel system component life. Caterpillar high ef-
ficiency fuel filters are the preferred filters for
Caterpillar engines.
i02962601
Fuel System Third Filter - NOTICE

Replace Care must be taken to ensure that fluids are contained
SMCS Code: 1261-510 ing, adjusting and repair of the product. Be prepared to
Personal injury can result from air pressure.
Personal injury can result without following prop- Dealer Service Tool Catalog” for tools and supplies
er procedure. When using pressure air, wear a pro- suitable to collect and contain fluids on Caterpillar
tective face shield and protective clothing. products.
Maximum air pressure at the nozzle must be less Dispose of all fluids according to local regulations and
than 205 kPa (30 psi) for cleaning purposes. mandates.
Note: Replace the primary fuel filter, the secondary

fuel filter and the third fuel filter during every change
interval. Also replace the primary fuel filter, the
Personal injury can result when using cleaner sol- secondary fuel filter and the third fuel filter when the
vents. indicator for the filter flashes. Refer to Operation and
Maintenance Manual, “Monitoring System” for more
To help prevent personal injury, follow the instruc- information.
er before using. Note: This fuel filter is the LAST filter before the
high pressure fuel system. Replace the filter
QUICKLY in order to avoid contamination. DO
NOT REMOVE the fuel filter from the packaging
until the filter is ready to be replaced.
Fuel leaked or spilled onto hot surfaces or electri- important to keep the fuel free from contamination.
cal components can cause a fire. As fuel system contamination usually occurs during
while working on the fuel system. • Only use clean fuel of the correct grade from
a reliable source.
battery when changing fuel filters. • Do not refuel from contaminated containers or
NOTICE
Do not fill the fuel filters with fuel before installing the
• Do not use contaminated equipment.
fuel filters. The fuel will not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
• Regularly clean the outside of the fuel filler cap
and the area around the fuel filler cap.
ated wear to fuel system parts.
142 SEBU8408-04
Maintenance Section
Fuel Tank Cap Filter and Strainer - Replace/Clean
• Only use Caterpillar approved fuel filters. The 5. Clean the filter mounting base. Make sure that all
use of Caterpillar filters is essential in order to of the used seal is removed.
protect the fuel system.
6. Coat the seal of the new filter with clean diesel
• Do not service the fuel filters prior to the fuel.
suggested maintenance interval. This may
increase the risk of contamination in the fuel Note: Before you install the fuel filter, do not
system. attempt to fill the fuel in the fuel filter.
Note: In order to reduce the risk of contamination 7. Install the new fuel filter by hand.
in the system, do not remove the primary fuel filter
and the third fuel filter simultaneously. Perform these Instructions for the installation of the filter are
operations separately. printed on the side of each Caterpillar spin-on
filter. For non-Caterpillar filters, refer to the
Note: After the engine has stopped, you must installation instructions that are provided by the
wait for 60 seconds in order to allow the fuel supplier of the filter.
pressure to be purged from the high pressure fuel
lines before any service or repair is performed 8. Prime the fuel system. See Operation and
on the engine fuel lines. Maintenance Manual, “Fuel System - Prime” for
instructions.
the machine in order to gain access to the third 9. Before you start the engine, make sure that the
fuel filter. drain valves are completely closed. Start the
engine. Check for leaks.
2. Ensure that the fuel supply valve (if equipped) is in
the OFF position. Place a suitable container under 10. Close the engine access cover.
the fuel filter in order to catch any fuel that might
spill. Clean up any spilled fuel. Reference: See “Fuel System Secondary Filter -
Replace” in this manual.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information on
i02960539
containing fluid spillage.
3. Before you replace the third fuel filter element,

Fuel Tank Cap Filter and
replace the primary fuel filter element. Strainer - Replace/Clean
Refer to the Operation and Maintenance Manual, SMCS Code: 1273-070-Z2; 1273-070-STR
“Fuel System Primary Filter - Clean/Replace” for
the replacement procedure.
g01478674
Illustration 198
Illustration 197
g01483593 1. Remove the fuel tank cap.
4. Clean the outside of the fuel filter. Use a Caterpillar 2. Disassemble the fuel tank cap.
strap wrench in order to remove the filter from the
engine and dispose of the filter in a safe place. 3. Inspect the seal on the fuel cap for damage. If the
seal is damaged, replace the seal. Lubricate the
Note: Always discard used filters according to local seal on the fuel tank cap.
regulations.
SEBU8408-04 143
Maintenance Section
Fuel Tank Water and Sediment - Drain
4. Inspect the debris boot on the fuel tank cap for

damage. if the debris boot is damaged, replace
the boot.
5. Replace the filter elements on the fuel tank cap.
6. Remove the strainer from the filler opening.
7. Wash the strainer from the filler opening.
8. Install the strainer.
9. Install the fuel tank cap.
g01193966
i02960555 Illustration 200
Fuel Tank Water and Sediment Left side view
- Drain 2. Open the drain valve with the yellow handle. Allow
the water and the sediment to drain into a suitable
SMCS Code: 1273-543-M&S container.
3. Close the drain valve. Close the access cover.
Personal injury or death may result from failure to i03138127

adhere to the following procedures.
Fuses and Circuit Breakers -
Replace/Reset
SMCS Code: 1417-510; 1420-529; 1420

g01195505
Illustration 201
Circuit Breaker/Reset – Push in the button in order

to reset the circuit breaker. If the electrical system is
working properly, the button will remain depressed.
g01478733
Illustration 199 If the button does not remain depressed, check the
appropriate electrical circuit. Repair the electrical
The drain valve is under the fuel tank at the rear of circuit, if necessary.
the machine.
1. Open the access cover.

144 SEBU8408-04
Maintenance Section
Fuses and Circuit Breakers - Replace/Reset
Replace 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.
g01615313
Illustration 202 The fuse panel is positioned behind the fuse cover
(A) Main breaker (105 Amp) on the left side of the machine near the battery
(B) Alternator circuit breaker (105 Amp) disconnect switch.
Remove the Fuse Cover

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.
The fuse panel is positioned behind the access door

on the left side of the operator seat.
g01481374
Illustration 203
1. Apply upward pressure to the lip of the cover at

top left corner and long side. This releases the
top of cover.
2. Apply upward pressure to the lip of the cover at

bottom left corner and long side. This releases the
bottom of cover.
3. Remove the cover.

SEBU8408-04 145
Maintenance Section
Fuses and Circuit Breakers - Replace/Reset
g01481376
Illustration 204
Fuse Block (1) Winch (13) – 15 Amp
Product Link (1) – 10 Amp 24V Converter (14) – 15 Amp
Rear Work Lights (2) – Relay Fuse Block (2)
Horn (3) – 10 Amp Monitor Display (15) – 10 Amp
Front Work Lights (4) – Relay Accugrade and GPS Radio Display (16) – 15 Amp
Dome Lamp (5) – 10 Amp Parking Brake and Handle (17) – 15 Amp
Ignition key (6) – 10 Amp 24V Converter (30) – 15 Amp
Rear Work Lights (7) – 15 Amp Accugrade and GPS Power Module (31) – 15 Amp
12 Volt Converter (8) – 15 Amp Brake Pedal (32) – 10 Amp
Front Work Lights (9) – 15 Amp Five spare fuses (Block 2) (33) – 15 Amp
Engine ECM (10) – 15 Amp One spare fuse (Block 2) (33) – 10 Amp
Machine ECM A4M1 (11) – 15 Amp Fuse Block (3)
Implement ECM A5M2 (12) – 15 Amp Blower Fan (18) – 15 Amp

146 SEBU8408-04
Maintenance Section
Hydraulic System Oil - Change
Front Work Lights (19) – 15 Amp
Condenser 1 (20) – 15 Amp

At operating temperature, the hydraulic tank is hot
and under pressure.
Condenser 2 (21) – 15 Amp
Precleaner (22) – 15 Amp
jury. Do not allow hot oil or components to contact
skin.
Side Window Wiper (23) – 15 Amp
Remove the filler cap only when the engine is
Windshield wipers, rear window wiper and
stopped, and the filler cap is cool enough to touch
washer pump (24) – 15 Amp
with your bare hand. Remove the filler cap slowly
in order to relieve pressure.
Precleaner (25) – Relay
Backlights (26) – 10 Amp

Lubricants
Beacon (27) – 10 Amp
Approved hydraulic oil must be used to obtain the
4000 hour hydraulic oil change. Refer to the list that
12V Converter (28) – 10 Amp
follows for approved oils.
Air Suspension Seat (29) – 15 Amp
Caterpillar Hydraulic Oils
One spare fuse (Block 3) (33) – 10 Amp
• “Cat HYDO Advanced 10”
4. Replace a fuse if the element separates.
• “Cat HYDO”
5. If the fuse of a particular electrical system requires
frequent replacement, check the electrical circuit. • TDTO
6. Repair the electrical circuit, if necessary. • TDTO (TMS)
• DEO SYN
i02960615
Hydraulic System Oil - Change • Cat Arctic DEO SYN
SMCS Code: 5050-044

• Cat Arctic TDTO SYN
Note: The normal hydraulic oil change interval

• Cat ECF-1-a, ECF-2, ECF-3
is at every 2000 Service Hours or 1 Year. By
performing S·O·S oil analysis, the hydraulic
• MTO
oil change interval may be extended to 4000
Service Hours or 1 Year. S·O·S oil analysis must
• Cat TO-4
be performed at every 500 Service Hours or
3 Months in order to extend the hydraulic oil
• Cat BF-1
change interval. The results from the S·O·S oil
analysis will determine if the hydraulic oil change Commercial Oils
interval may be extended. If S·O·S oil analysis is
not available, the hydraulic oil change interval Commercial oils with a minimum zinc content of 900
must remain at every 2000 Service Hours or 1 ppm that meet Cat ECF-1, ECF-2, ECF-3, or the Cat
Year . Refer to the Operation and Maintenance TO-4 specification can be used. Also, acceptable
Manual, “Hydraulic System Oil Sample - Obtain”. commercial oils must have an SAE viscosity grade
of one of the following SAE specs.
Machines that are used in severe conditions are
not included in the 4000 hour maintenance interval. • SAE10W
Machines that are used in severe conditions must
use the interval in the Maintenance Interval Schedule. • SAE0W20
• SAE0W30
SEBU8408-04 147
Maintenance Section
Hydraulic System Oil - Change
Note: Industrial hydraulic oils are not recommended 10. Install the filler strainer.
for the hydraulic systems of Caterpillar machines.
Industrial hydraulic oils are more likely to allow 11. See Operation and Maintenance Manual,
corrosion and industrial hydraulic oils are more likely “Capacities (Refill)” in order to determine the
to allow excessive wear. amount of hydraulic oil that is needed to fill the
hydraulic oil tank. Fill the hydraulic oil tank with
Change the Hydraulic Oil the appropriate oil.
12. Inspect the filler cap gasket. Replace the gasket if

Operate the machine in order to warm the oil.
damage or wear is evident.
Park the machine on level ground. Lower the
13. Install the filler cap.
bulldozer blade to the ground and apply slight
downward pressure. Engage the parking brake and
14. Start the engine. Run the engine for a few
stop the engine.
minutes.
g01321368
Illustration 205 g01194009
Illustration 206
Right side view
1. Remove the hydraulic tank filler cap slowly in
order to relieve any pressure.
15. Maintain the oil level to the “FULL” mark in the
sight gauge. Add oil, if necessary.
2. Wash the filler strainer and the filler cap in a clean
nonflammable solvent.
16. Stop the engine.
3. Remove the oil drain plug. The oil drain plug is
located under the right rear of the machine. Reference: See Special Publication, SEBU6250,
“Caterpillar Machine Fluid Recommendations”,
“Sampling Interval Schedule and Location of
4. Attach a hose to a 1 inch NPT pipe nipple. This
1 inch NPT pipe nipple should have a length of Sampling Valve”, Special Publication, SEBU6250,
“Caterpillar Machine Fluid Recommendations”,
100 mm (4 inch).
“S·O·S Oil Analysis”, and Special Publication,
5. Install the pipe nipple into the drain plug opening. SEBU6250, “Caterpillar Machine Fluid
Recommendations”, “Lubricant Viscosities”for
additional information.
6. Rotate the pipe nipple clockwise in order to open
the internal drain valve. Allow the oil to drain into a
suitable container.
7. Remove the pipe nipple. 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 N·m
(50 ± 5 lb ft).
9. See Operation and Maintenance Manual,

“Hydraulic System Oil Filter - Replace”. Change
the hydraulic system filter.
148 SEBU8408-04
Maintenance Section
Hydraulic System Oil Filter - Replace
i03469640
Hydraulic System Oil Filter -

Replace
SMCS Code: 5068-510
At operating temperature, the hydraulic tank is hot

and under pressure.

jury. Do not allow hot oil or components to contact
g01194147
skin. Illustration 208
Remove the filler cap only when the engine is 3. Remove the filter element (2). Properly discard
stopped, and the filler cap is cool enough to touch the filter element.
with your bare hand. Remove the filler cap slowly
in order to relieve pressure. Apply a thin coat of oil to the seal on the new filter.
4. Install the filter element by hand. When the

NOTICE seal contacts the base, tighten the nut with an
Care must be taken to ensure that fluids are contained additional 3/4 turn.
ing, adjusting and repair of the product. Be prepared to 5. Remove the retainer ring from the oil filler tube.
ing any compartment or disassembling any compo- 6. Remove the strainer from the oil filler tube.
7. Wash the screen in a clean nonflammable solvent.
Dealer Service Tool Catalog” for tools and supplies 8. Inspect the seal on the filler cap. Replace the seal
suitable to collect and contain fluids on Caterpillar if the seal is worn or if the seal is damaged.
products.
9. Install the strainer, the retainer ring, and the cap.
mandates.
1. Lower the bulldozer and the ripper to the ground.
g01194009
Illustration 209
10. Maintain the hydraulic oil to the “FULL” mark in

the sight gauge.
g01321384
Illustration 207
2. Slowly remove the hydraulic tank filler cap (1) in

order to relieve the pressure in the hydraulic oil
system.
SEBU8408-04 149
Maintenance Section
Hydraulic System Oil Level - Check
Replace the Case Drain Filter i02568458
Hydraulic System Oil Level -

Check
SMCS Code: 5056-535-FLV; 7479
g01321395
Illustration 210
1. Open the access door on the right side of the

machine.
g01321368
Illustration 212
The hydraulic tank is on the right rear side of the

machine.
g01604335
Illustration 211
2. Use a strap type wrench to remove the filter

element. Dispose of the used filter element
properly.
g01194009
Illustration 213
3. Clean the filter mounting base. Make sure that all
of the used gasket is completely removed. 1. Maintain the oil level to the “FULL” mark in the
sight gauge.
4. Apply a thin coat of oil to the seal on the new filter.
Install a new hydraulic oil filter by hand. 2. If the hydraulic system requires additional
hydraulic oil, remove the filler cap and add oil
Note: Instructions for the installation of the filters are through the filler tube. Refer to Illustration 212.
For non-Caterpillar filters, refer to the installation 3. Clean the filler cap and install the filler cap.
filter.
150 SEBU8408-04
Maintenance Section
Hydraulic System Oil Sample - Obtain
i03469903 3. Use a 169-8373 Fluid Sampling Bottle in order

to obtain a sample.
Hydraulic System Oil Sample
- Obtain 4. Replace the protective cap.
SMCS Code: 5095-008 5. Close the engine access door on the left side of
the machine.
NOTICE
Care must be taken to ensure that fluids are contained i02106227
ing, adjusting and repair of the product. Be prepared to Oil Filter - Inspect
ing any compartment or disassembling any compo- SMCS Code: 1318-507; 3067-507; 5068-507
Inspect a Used Filter for Debris
products.

mandates.
g00100013
Illustration 216
The element is shown with debris.
Use a filter cutter to cut the filter element open.

Spread apart the pleats and inspect the element for
metal and for other debris. An excessive amount of
g01481308 debris in the filter element can indicate a possible
Illustration 214 failure.
1. Open the engine access door on the left side of If metals are found in the filter element, a magnet can
the machine. be used to differentiate between ferrous metals and
nonferrous metals.
Ferrous metals can indicate wear on steel parts and

on cast iron parts.
Nonferrous metals can indicate wear on the

aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.
Small amounts of debris may be found in the filter

element. This could be caused by friction and by
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount
of debris is found.
g01811035
Illustration 215
2. Remove the protective cap from sampling port (1).

SEBU8408-04 151
Maintenance Section
Pivot Shaft Oil Level - Check
Using an oil filter element that is not recommended i02596594

by Caterpillar can result in severe engine damage
to engine bearings, to the crankshaft, and to other Power Angling Tilt
parts. This can result in larger particles in unfiltered
oil. The particles could enter the lubricating system
Pins-Lubricate
and the particles could cause damage. SMCS Code: 6052; 6701
i02568466
Pivot Shaft Oil Level - Check

SMCS Code: 4153-535-FLV

jury.

skin.
g01299728
Illustration 218
g01321475
Illustration 217
g01314179
Illustration 219
The oil plugs for the pivot shafts are located on both sides of the
machine.
Apply lubricant to the grease fittings for the head
1. Remove the oil plug on one side of the machine. end of the lift cylinder (1) and the rod end of the lift
cylinder (2). Be sure to lubricate the left and right
2. Check the pivot shaft oil level. The oil level should side lift cylinders.
be at the bottom of the threaded hole.
Apply lubricant to the remote grease fitting for
3. If necessary, add oil in order to bring the oil level the head end of the angle cylinder (3). Also apply
up to the bottom of the threaded hole. lubricant to the grease fitting for the rod end of the
angle cylinder (5). Be sure to lubricate the left and
4. Repeat the procedure on the other side of the right side angle cylinders.
machine.
Apply lubricant to the grease fittings for the rod end
of the tilt cylinder (6) and the head end of the tilt
cylinder (7).
Apply lubricant to the grease fitting on the bearing

for the blade (4). Be sure to lubricate both fittings on
the bearing.
152 SEBU8408-04
Maintenance Section
Radiator Core - Clean
i02568652
Radiator Pressure Cap -

Clean/Replace
SMCS Code: 1353-070-Z2; 1353-510-Z2
g01314177
Illustration 220
Apply lubricant to the remote grease fitting for the

pivot pin on the main C-frame (8). Be sure to lubricate
the left and right side pivot pins.
g01286873
i02568502 Illustration 222
Radiator Core - Clean 1. Open radiator access door (1) on top of radiator
guard (2).
SMCS Code: 1353-070; 1805; 1810
g01286875
Illustration 223
g01286761
Illustration 221
2. Slowly remove radiator cap (3) in order to relieve
You can use compressed air, high pressure water, system pressure.
or steam to remove dust and other debris from the
radiator core. However, the use of compressed air 3. Inspect the radiator cap for damage, for deposits,
is preferred. or for foreign material. Clean the radiator cap
with a clean cloth. Replace the radiator cap if the
See Special Publication, SEBD0518, “Know Your radiator cap is damaged.
Cooling System” for the complete procedure for
cleaning the radiator core. 4. Install radiator cap (3). Close radiator access door
(1).
SEBU8408-04 153
Maintenance Section
Recoil Spring Compartment Oil Level - Check
i03363841 i03126940
Recoil Spring Compartment Ripper Linkage and Cylinder

Oil Level - Check Bearings - Lubricate
SMCS Code: 4158-535-OC SMCS Code: 6313-086-BD, L4

jury.

skin.
g01604054
Illustration 226
1. Lubricate the four fittings (1) for the link pin on

each side of the ripper.
2. Lubricate two fittings (2) at the top of the cylinder.

Lubricate one fitting (3) at the bottom of the
cylinder.
g01736181
Illustration 224
i02696402
1. Remove all of the debris around the cover plate
on the top of the track roller frame.
Ripper Tip - Inspect/Replace
SMCS Code: 6808
2. Remove the cover plate for the oil filler. Observe
the level of the oil.
When the ripper tip is worn close to the shank,
replace the ripper tip. 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 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.

g00100922
Illustration 225
5. Install the pin from the opposite side of the
3. Maintain the oil level to the level mark on the cast retainer.
surface.
6. Raise the ripper and remove the blocking.
4. Install the cover plate.
7. Lower the ripper to the ground.
5. Repeat the procedure for the other recoil
compartment.
154 SEBU8408-04
Maintenance Section
Rollover Protective Structure (ROPS) - Inspect
i02568660
Rollover Protective Structure

(ROPS) - Inspect
SMCS Code: 7325-040
g00932801
Illustration 228
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
Illustration 227
g01321857 bolts are tight.
Inspect the Rollover Protective Structure (ROPS) Check buckle (2) for wear or for damage. If the buckle
for bolts that are loose or damaged. Replace any is worn or damaged, replace the seat belt.
damaged bolts and any missing bolts with original
replacement parts only. Tighten the bolts to a torque Inspect the seat belt (3) for webbing that is worn or
of 800 ± 100 N·m (590 ± 74 lb ft). frayed. Replace the seat belt if the seat belt is worn
or frayed.
Note: Apply oil to all bolt threads for the ROPS before
you install the bolts. Improper bolt torque can result if Consult your Caterpillar dealer for the replacement of
you do not apply oil to the threads. the seat belt and the mounting hardware.
Do not weld reinforcement plates to the ROPS Note: Within three years of the date of installation or
in order to straighten the ROPS. Do not weld within five years of the date of manufacture, replace
reinforcement plates to the ROPS in order to repair the seat belt. Replace the seat belt at the date which
the ROPS. occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
If the ROPS has any cracks in the welds, in the buckle, and the seat belt retractor.
castings, or in any metal section, consult your
Caterpillar dealer for repairs. If your machine is equipped with a seat belt
extension, also perform this inspection procedure for
the seat belt extension.
i02429589
Seat Belt - Inspect i02429594
SMCS Code: 7327-040; 7520 Seat Belt - Replace

Always check the condition of the seat belt and the SMCS Code: 7327-510
condition of the seat belt mounting hardware before
you operate the machine. Replace any parts that are Within three years of the date of installation or within
damaged or worn before you operate the machine. 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.
SEBU8408-04 155
Maintenance Section
Steering Charge Filter - Replace
g01152685
Illustration 229
(1) Date of installation (retractor) Illustration 231
g01810843
(2) Date of installation (buckle)
(3) Date of manufacture (tag) (fully extended web)
(4) Date of manufacture (underside) (buckle) 2. Use a strap type wrench to remove the filter
element. Dispose of the used filter element
Consult your Caterpillar dealer for the replacement of properly.
the seat belt and the mounting hardware.
3. Clean the filter mounting base. Make sure that all
If your machine is equipped with a seat belt of the used gasket is completely removed.
extension, also perform this replacement procedure
for the seat belt extension. 4. Apply a thin coat of oil to the seal on the new
steering charge filter. Install the new steering
charge filter.
i03469960
Steering Charge Filter - Note: Instructions for the installation of the filters are
Replace For non-Caterpillar filters, refer to the installation
SMCS Code: 431F filter.
i02961474
Track - Check/Adjust
SMCS Code: 4170-036
g01481308
Illustration 230
1. Open the engine compartment door on the left

g01285966
Illustration 232
Check the track adjustment. Check the track for wear

and for excessive dirt buildup.
If the track appears to be too tight or too loose,

perform the following adjustments.
156 SEBU8408-04
Maintenance Section
Track - Check/Adjust
The correct adjustment for track sag is the sum of

dimension (A) plus dimension (B) divided by 2 equal
45 ± 5 mm (1.77 ± 0.20 inch).
Grease is under high pressure.
Grease coming out of the relief valve under pres- Loose Track Adjustment
sure can penetrate the body causing injury or
death.
Do not watch the relief valve to see if grease is es-

caping. Watch the track or track adjustment cylin-
der to see if the track is being loosened.
Loosen the relief valve only one turn.
Move the machine forward. Allow the machine to

stop without the use of the service brakes. Adjust the
tracks while you are in the machine's typical operating
conditions. If packing conditions prevail on the job,
the tracks should be adjusted with packing material.
g01321879
Illustration 235
1. Remove the valve cover plate.
g01286908
Illustration 233
NOTICE
Do not attempt to tighten track when dimension (1) is Illustration 236
g01286912
105 mm (4.13 inch) or more.
2. Add multipurpose grease (MPGM) through
Contact your Caterpillar dealer for track service or in- track adjustment valve (4). Add the MPGM until
structions. dimension (A) and dimension (B) are correct.
3. Operate the machine back and forth in order to

equalize the pressure. Allow the machine to coast
to a complete stop. Do not use the brakes.
4. Remeasure dimension (A) and dimension (B).
Reference: See Operation and Maintenance

Manual, “Front Idler Position - Check” for additional
information on SystemOne Undercarriage .
Tight Track Adjustment

1. Loosen relief valve (5) by one turn of 360 degrees.
g01481313 Allow the grease to escape.
Illustration 234
2. Close the relief valve.

SEBU8408-04 157
Maintenance Section
Track Roller Frame - Inspect
3. Add MPGM through track adjustment valve (4). i02568939

Add grease until dimension (A) and dimension (B)
are correct. Track Roller Frame - Inspect
SMCS Code: 4151-040
Bolt Torque for Track Shoes
SystemOne Undercarriage
The torque requirement for track shoe bolts is
400 ± 70 N·m (300 ± 50 lb ft). Tighten the bolts for
an additional 120 degrees. If you are using bolts
with a master link, tighten the bolts to a torque of
400 ± 70 N·m (300 ± 50 lb ft). Tighten the bolts for an
additional 120 degrees.
Recoil Spring Compartment (Oil

Level Check)
g01322285
Illustration 238
Inspect the track roller frame for leaks.

jury.
i01989303
skin.
Transmission Magnetic Screen
- Clean
SMCS Code: 3030-070-MGS
If the transmission oil pump fails, remove the

transmission oil screen. Clean the screen. If the
transmission is disassembled for any reason, remove
the transmission oil screen. Clean the screen. Before
you remove any screen, drain the transmission.
1. Remove the bottom guard in order to gain access

to the transmission screen.
g01286915
Illustration 237
1. Maintain the oil level up to the mark.
2. Install the valve cover plate.
3. Repeat the procedure for the recoil compartment

on the other side of the machine.
g00864088
Illustration 239
2. Remove the bolts, the washers and the screen

housing. The magnetic filter and the suction
screen are located in the screen housing.
3. Remove the seals.

158 SEBU8408-04
Maintenance Section
Transmission Oil - Change
4. Wash the screen and the magnetic filter in a clean, 4. Clean the transmission magnetic screen.
nonflammable solvent. See Operation and Maintenance Manual,
“Transmission Magnetic Screen - Clean”.
5. Replace the seals.
6. Install the suction screen and the magnetic filter

in the screen housing.
7. Install the screen housing with the washers and

the bolts.
8. Install the bottom guard.
i03440640
Transmission Oil - Change

SMCS Code: 3030; 3080-044 g01790393
Illustration 241
Some components are removed for clarity.
5. Open the access door for transmission oil filler

Hot oil and components can cause personal in- cap (2). The access door is on the left side of the
jury. machine.
Do not allow hot oil or components to contact 6. Remove the transmission oil filler cap.
skin.
7. Add oil. Maintain the oil level to the “FULL” mark
Operate the engine in order to warm the oil. Park the on the dipstick (3).
machine on level ground. Lower all attachments to
the ground. Apply slight downward pressure. Note: To determine the correct amount of oil, see
Operation and Maintenance Manual, “Capacities
Engage the parking brake switch. Stop the engine. (Refill)”.
8. Clean the transmission oil filler cap (2) and install

the transmission oil filler cap.
9. Unscrew the transmission breather (1) and

remove the transmission breather.
10. Wash the transmission breather (1) in a clean

nonflammable solvent.
11. Install the transmission breather.
i03361825
g01322290
Transmission Oil Filter -
Illustration 240
Replace
1. Remove the transmission oil drain plug. Use a
4C-8563 Drain Adapter to open the internal drain SMCS Code: 3067-510
valve. Drain the oil into a suitable container.
2. Remove the drain adapter. Clean the transmission

oil drain plug and install the transmission oil drain Hot oil and components can cause personal in-
plug. jury.
3. Change the filter element. See Operation and Do not allow hot oil or components to contact
Maintenance Manual, “Transmission Oil Filter - skin.
Replace”.
SEBU8408-04 159
Maintenance Section
Transmission Oil Level - Check
Initially, replace the transmission oil filter after 250

service hours. Thereafter, replace the transmission
oil filter after every 1000 service hours.
The transmission oil filter is located at the rear of the

machine.
g01481344
Illustration 244
8. Open the front access door on the left side of the

cab.
g01322294
Illustration 242
1. Open the access door in the rear of the machine.
g01481351
Illustration 245
9. Maintain the oil level to the “FULL” mark on

dipstick (2). If necessary, add oil through filler tube
(1).
g01194845
Illustration 243
10. Stop the engine.
2. Remove the filter element cover assembly.
i02961534
3. Remove the filter element and properly discard
the filter element. Transmission Oil Level - Check
4. Clean the filter element housing with a clean cloth. SMCS Code: 3030-535-FLV; 3080-535-FLV
5. Inspect the seal. If the seal is damaged, replace

the seal.
6. Install the new filter element. Install the filter Hot oil and components can cause personal in-
element housing. jury.
7. Start the engine. Do not allow hot oil or components to contact

skin.
160 SEBU8408-04
Maintenance Section
Transmission System Oil Sample - Obtain
i02392209
Transmission System Oil

Sample - Obtain
SMCS Code: 3030-008

jury.

skin.
g01481344
Illustration 246
The transmission oil dipstick is behind the access NOTICE

cover on the left side of the machine. Care must be taken to ensure that fluids are contained

products.

mandates.
g01481351 Obtain the sample of the transmission oil as close as

Illustration 247
possible to the recommended sampling interval. The
recommended sampling interval is every 500 service
1. Open the access cover. Check dipstick (2) when
hours. In order to receive the full effect of S·O·S oil
the engine is running at low idle and the oil is at analysis, you must establish a consistent trend of
operating temperature. Maintain the oil between
data. In order to establish a pertinent history of data,
the “LOW” mark and the “FULL” mark.
evenly space the oil samplings. Be consistent with
the oil samplings.
Note: When you are operating the machine on severe
slopes, the quantity of oil in the transmission can be
If the machine is operated under a high load
increased up to 10 percent. When you are operating and/or under high temperature conditions,
with the increased oil quantity, prolonged operation
sample all fluids at the 250 hour interval.
in some machines can cause high transmission oil
temperatures. After the work on the severe slopes 1. Open the access cover in the rear of the machine.
has been completed, drain the excessive oil quantity
from the transmission.
2. Remove filler cap (1). If necessary, add oil.
3. Clean the filler cap and install the filler cap.
Replace the filter element if the transmission

oil filter indicator comes on during operation.
See Operation and Maintenance Manual,
“Transmission Oil Filter - Replace”.

SEBU8408-04 161
Maintenance Section
Winch Cable - Inspect
g01195011 g01960006
2. Remove the protective cap from the sampling 1. Press the FREE SPOOL switch.
valve.
2. Unreel the winch cable by manually pulling the
3. Use 177-8373 Sampling Bottle (Group) and winch cable.
8T-9208 Probe Assembly in order to obtain a
sample. 3. Inspect the entire cable for fraying or kinking. If
fraying or kinking is present, replace the winch
4. After you take a sample, remove the cap with the cable.
probe from the bottle, if necessary. Discard the
cap with the probe. Install the sealing cap that is
i03652657
provided with 169-7372 Fluid Sampling Bottle.
5. Replace the protective cap on the sampling valve.

Winch Cable - Replace
SMCS Code: 5163-510
Reference: Refer to , “Lubricant Viscosities” in the

Maintenance Section of this manual for the correct
fluid for your machine. Wear leather gloves when handling the winch ca-
ble.
i03652513
NOTICE
Winch Cable - Inspect Unroll the wire rope cable from the spool. Never lift the
wire rope off the spool in coils.
SMCS Code: 5163-040
NOTICE
Use the correct size ferrule for the winch cable in order
Wear leather gloves when handling the winch ca- to attach the winch cable to the load drum. Never use
ble. a knot in order to secure the winch cable to the load
drum.
Table 22
Line Load
Wire Rope Diameter Load Drum(1)
Recommended 19 mm 122 m (400 ft)
(0.75 inch)
Optional 22 mm
88 m (289 ft)
(0.875 inch)
(1) Capacity
162 SEBU8408-04
Maintenance Section
Winch Drum Bearing - Lubricate
Table 23
Winch Capacity
PA 55 Winch Bare Drum Full Drum
Standard Speed (Gearing)
Maximum Line 31388 kg 31388 kg
Pull (69200 lb) (69200 lb)
Maximum Line 45 m/min 78 m/min
Speed (147 ft/min)(2) (257 ft/min)(2)
Slow Speed (Gearing)
Maximum Line 31388 kg 31388 kg
Pull (69200 lb) (69200 lb)
g01010176
Maximum Line 18.6 m/min 32.6 m/min Illustration 251
Speed (61 ft/min)(2) (107 ft/min)(2)
(2) Maximum line speed is the no-load speed at the maximum Apply lubricant to the fittings for the winch drum.
line pull.
i01941203
For the correct procedure to replace the winch cable,
refer to Specifications, Systems Operation, Testing
and Adjusting, Disassembly and Assembly, “Cable
Winch Fairlead Rollers -
- Remove and Install” for the winch hydrostatic Lubricate
systems.
SMCS Code: 5163-086
i01941201
Winch Drum Bearing -

Lubricate
SMCS Code: 5159-086-BD
g01010852
Illustration 252
Apply lubricant to all six of the fairlead grease fittings.
i03188188
Illustration 250
g01010198 Winch Oil - Change
SMCS Code: 5163-044
1. Park the machine on level ground.

SEBU8408-04 163
Maintenance Section
Winch Oil Level - Check
Note: The oil must be filled to the bottom of the port

of the oil level check plug.
4. Fill the winch case with oil until the oil is at the
proper level.
5. Install plug (2). Tighten to a torque of 175 ± 15 N·m

(130 ± 10 lb ft).
i01953481
Winch Oil Sample - Obtain

SMCS Code: 5163-008; 7542
g01626970
Illustration 253
(1) Oil drain plug
(2) Oil filler plug
2. Remove drain plug (1) and allow the oil to drain

in a suitable container.
Note: To help drain the oil, remove oil filler plug (2).
3. Install plug (1) after all of the oil has been drained.
Tighten plug (1) to a torque of 175 ± 15 N·m
(130 ± 10 lb ft).
4. Refill the winch to the proper level. Install plug (2).

g01011913
Illustration 255
i03188221
Remove the filler plug for the winch. Obtain a sample
Winch Oil Level - Check of the winch oil by pulling a sample through the filler
plug opening.
SMCS Code: 5163-535-FLV
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations”, “S·O·S Oil
Analysis” for information that pertains to obtaining a
sample of the winch oil. Refer to Special Publication,
PEHP6001, “How To Take A Good Oil Sample” for
more information about obtaining a sample of the
winch oil.
g01626970
Illustration 254
(1) Drain plug
(2) Oil filler plug and oil level check
1. Position the machine on a flat, level surface.
2. Inspect the winch for leaks. Repair any leaks.
3. Remove oil level check plug (2) for a quick check

of the oil level.
164 SEBU8408-04
Maintenance Section
Winch Vent Plug - Clean
i01941200
Winch Vent Plug - Clean

SMCS Code: 5163-070-VN
g01803334
Illustration 258
Window Washer – The washer fluid bottle

is on the left side of the machine. Open the
g01010194
access door. Remove the fluid bottle cap in
Illustration 256 order to fill the washer fluid bottle.
1. Remove the vent plug.
i02569551
2. Clean the vent plug in a suitable solvent.
Window Wipers -
3. Install the vent plug.
Inspect/Replace
Note: Do not replace the vent plug with a solid plug.
SMCS Code: 7305-040; 7305-510
Damage to the winch will occur.
i03460343
Window Washer Reservoir -

Fill
SMCS Code: 7306-544
NOTICE
When operating in freezing temperatures, use
Caterpillar or any commercially available nonfreezing
window washer solvent.
g01322320
Illustration 259
Inspect the front window wiper blade, the right

window wiper blade, the left window wiper blade,
and the rear window wiper blade. Replace any wiper
blades that are damaged or worn. Replace any wiper
blades that streak the window.
i01411798
Windows - Clean
SMCS Code: 7310-070; 7340-070
g01481344
Illustration 257
Use commercially available window cleaning
solutions to clean the windows.
SEBU8408-04 165
Maintenance Section
Windows - Clean
g00743092
Illustration 260

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Excerpted from Operation & Maintenance Manual (SEBU8408-04)

i03620028 Every 10 Service Hours or Daily

Every 500 Service Hours or 1 Year

Every 1000 Service Hours

Every 1000 Service Hours or 6 Months

Every 2000 Service Hours or 1 Year

Every 3000 Service Hours or 2 Years

Every 3 Years After Date of Installation or

Every 6000 Service Hours or 3 Years

i02959862 The nonadjustable backup alarm is set at the

Tighten the battery retainers on all batteries at every

1. Open the battery access cover.

2. Clean the top of the batteries with a clean

3. Close the battery access cover.

Apply the service brakes. Disengage the parking Belt - Inspect/Replace

2. Open the engine enclosure.

The backup alarm is on the rear of the machine.

2. Park the machine on level ground. Move the

3. Open the engine enclosure.

4. Turn the battery disconnect switch to the OFF

5. Remove the three bolts and the two nuts in order

6. Release the tension on serpentine belt (1). Insert

7. Remove the belt from the pulleys. Feed the belt

8. Install the new belt around the pulleys.

Replace The internal circuits, the indicators, and the gauges

Turn on all of the machine lights. Check for proper

Move the machine forward and test the service

Braking System (Test)

If the machine moves during the test, reduce the

If the machine moved while testing the brakes,

g01477945 Note: The machine can drive through the brakes

• All indicators of units (Deg C, kPa, rpm, and liters)

• The gear/direction readout shows “* *”. Illustration 154

Cab Filter (Recirculation) -

Note: Inspect the filters and clean the filters more

Note: Remove both of the recirculation filters from

2. Clean the filter elements with low pressure air.

Note: Do not use air pressure higher than 200 kPa

3. Look through the filter toward a bright light. Inspect

Cooling System Coolant

5. Inspect the filler cap gasket. Replace the filler cap

For additional information about adding an extender, Cooling System Coolant

Note: It is not necessary to obtain a Coolant

• Obtain coolant samples directly from the coolant

• Keep the lids on empty sampling bottles until you

• Place the sample in the mailing tube immediately

• Never collect samples from expansion bottles.

g01478193 • Never collect samples from the drain for a system.

4. Close the left engine access door.

Submit the sample for Level 1 analysis.

For additional information about coolant analysis, see

1. Open the left engine access door.

i02960132 Use the following guidelines for proper sampling of

• Place the sample in the mailing tube immediately

• Never collect samples from expansion bottles.

4. Close radiator access door (1).

Submit the sample for Level 2 analysis.

Cooling System Extended Life

Reference: For information about adding an

Flushing the ELC from the Cooling

Flushing a Standard Coolant from

6. While the engine is stopped, flush the system with