PM MG915,917,919,921,922

Preventive maintenance-MG915，917，919，921，922
Caterpillar: Confidential Green

catalog
Chapter1.maintenance point and method introduction
1.1 Engine part
1.2 transmission and brake system
1.3 hydraulic system
1.4 work implement , front axle , rear axle
1.5 front and rear frame articulate
1.6 electric and others
Chapter2. adjustment method
2.1 blade
2.2 spinning disc
2.3 blade lifting cylinder bracket
2.4 center frame cylinder bracket
2.5 drawbar ball and socket clearance
Chapter3.Oil for maintenance

1.1 Engine part
Introduce D9 engine maintenance
Air filter
belt
Diesel filter
Engine oil filter coolant filter Engine dipstick

1.1 Engine part
Clean method of air filter primary element
Removing procedure,
1.Remove the cap of air filter housing
2.take out primary element
3.Use less than 207kpa compressed air, along the element wrinkle direction, blow the element
from inside to outside, and clean the filter inner wall and housing.do not use tool to knock inner
wall and housing ,do not use oil or water to wash filter and element.

1.1 Engine part
Clean method of air filter primary element
Installing procedure
1.Install cleaned air filter primary element and cap
2.Reset air filter indicator
3.Check the gap between cap and air filter housing and no leakage.
Note : when indicator appear red color ,need clean primary element which can be cleaned six times. the
second element can not be cleaned , only is replaced, if you find it is polluted , should replace together with
primary element.
indicator
Normal status Maintenance status

1.1 Engine part
replacement method of air filter primary element
Replacing procedure： Clean housing

1.Remove air filter cap and take out primary element
2.Take out second element
3. Clean air filter housing inner
4.Install new second element
5.Install new primary element
6.Install air filter cap and tighten
7.Press indicator top button make it reset. Replace second
element
Note,
Check inlet air passage must have no gap, when
primary element can be cleaned 6times,at this
time, primary and second element should be
replaced together. Replace primary
element

1.1 Engine part
Coolant filter replacement method
Operating procedure
1. Use special tool remove coolant from engine.
2.When to install new filter must smear short oil on the seal , after installing the coolant filter to support, first use hand
tighten then use special tool tighten 3/4 circle to 1 circle
Coolant filter remove Smear oil

1.1 Engine part
Coolant check method
Check procedure
1.Check coolant level of expansion tank , this level should be in the middle level of sight glass.
2.If lack , need add same type coolant to prevent occur chemical reaction.
Middle level of sight glass

Level of sight glass

1.1 Engine part
Coolant replace method Tank drain switch
Replace procedure
1.Open tank cap , tank bottom drain switch and engine
body drain switch , make the coolant flow to container.
2.Then close tank bottom drain switch and engine body
drain switch.
3.Fill coolant to sight glass middle level.
4.Fasten tank cap.
Body drain
Note. switch
the type of coolant is YF-2,and it should be replaced
every two years.

1.1 Engine part
Fuel filter/water separator replace method
Replace procedure：
1. open drain switch
2. remove ‘fuel filter/water separator” from engine
3. smear oil on new seal
4. after the seal contact with support then tighten ¾ circle to
1 circle. ； Fuel
filter/water
5. Before work should check “fuel filter/ water separator” separator
and drain water in time. 6.under the normal status ,should
replace this filter every 250h. Drain
valve

1.1 Engine part
Diesel filter replacement method
Operating procedure：
1.remove
clean the top and around of diesel filter , then use special tool remove filter . Note, this filter only use one
time.
2.Install
1.First smear oil on the seal before install filter
2.Install filter , after seal contacting with the support ,then use special tool tighten ¾ circle.
3.Release vent screw and press transfer pump to drain air of low pressure pipe and diesel filter , until the
diesel flowed from vent screw doesn’t have air , then tighten vent screw.
Remove filter Smear oil Tighten with special tool Vent screw

1.1 Engine part
Stage III Diesel filter
The remove & Install method is same with stage II engine.
Drain
valve
Primary Secondary Drain water Triple

diesel filter, diesel filter special tool filter

1.1 Engine part
Diesel tank cap and inner filter cleaning method
Operating procedure,
1.Open the diesel tank cover and check
the O ring of diesel tank cover if it is
damaged.
２clean filter element.
Filter element o ring

1.1 Engine part

Impurity in the diesel tank cleaning method
Remove the drain oil bolt under the diesel tank to drain the impurity in the tank.
Drain oil bolt is located on the right side of machine.

1.1 Engine part
Belt replacement method
Operating procedure.
1.insert tension wheel with curved rod rotate clockwise to release belt
2 .take away belt from belt wheel
belt
3. install new belt and loose belt tension device.
Curved rod
tension wheel

1.1 Engine part

Diesel oil level checking method
After engine shut down 5 minutes then pull dipstick to check the oil level which should be in the
middle of top line and bottom line.
Top line Bottom line
dipstick

1.1 Engine part
Engine oil and oil filter replacement method
1. Remove
Replace oil when engine is hot status. Safe caution
prevent to scald by hot oil ,Open engine oil drain plug
then drain oil
Remove oil filter element
connector
Drain plug

1.1 Engine part

Engine oil and oil filter replacement method
2. install
1.First smear oil on the seal before install filter
2.Install filter , after seal contacting with the support
,then use special tool tighten ¾ to 1 circle.
3.Release vent screw and press transfer pump to drain Smear
air of low pressure pipe and diesel filter , until the
diesel flowed from vent screw doesn’t have air , then oil
tighten drain oil plug.
3.filler
fill new oil, After engine shut down 5 minutes then
pull dipstick to check the oil level which should be in
the middle of top line and bottom line.


Gear box oil level checking method
Check gear box hydraulic oil should keep machine be in idle speed status.
The oil level should be in the middle of center line and bottom line when the oil temperature is 40 centigrade.
The oil level should be in the middle of center line and top line when the oil temperature is 80 centigrade.
dipstick

1.2 transmission and brake system remove

Filter of gear box replacement method
1. Clean around of filter

2. Remove filter with special tool Smear oil
3. Smear oil on the new filter seal
4. Spin the filter to gear box support then tighten 1/3 to
½ circle.
install
Note. when to replace oil must replace
filter together.


Gear box oil replacement method
1.Remove drain oil cap and make the oil flow into
container.
2.Fill around 28L engine oil into the gear box ,the oil Drain oil cap
type is SAE15W-40.
2.Start engine and keep a few minutes in idle speed Filler cap
until the gear box arrive to a certain temperature , then
spin the dipstick to check if it is in standard scope.
Note. if replace gear box oil should change gear
box filter together.


Balance box oil level checking method
1.Lay MG on the smooth ground.
2.Remove oil level plug and observe the oil
position , the lower bound is at a distance from the
oil hole bottom bus 8mm.
reminder . the position of oil hole at front and inside
of balance box.
oil level plug


Balance box oil replacement method
Operating procedure： oil level plug and filler plug
1.Lay the machine on the 20 degree slope and

the rear wheel on the high position ,then loose
drain oil plug and make the oil flow into
container.
2.Make the machine in horizontal position When
to fill.
3.The oil quantity should be controlled at a
distance of balance box sight glass bottom bus
and allow a little small spill. v
Drain oil plug


Main reducer oil level checking method
Remove oil level plug and observe oil level position ,the lower position is at a distance
from oil level hole bottom bus 8mm.
Main reducer oil level hole

Main reducer oil replacement method
Remove drain oil plug and make the oil flow to

container.
Ensure the axle in straight position , the
quantity of filler should be controlled at a
distance from filler plug bottom bus . and allow
a little small slopping. Drain oil plug
Main and planetary reducer group need fill

around 33 L.
Main reducer filler hole


Brake accumulator oil level checking method
Open oil cup cap and check brake fluid level and the level should be higher 20mm than filter
element .
Note. the brake fluid cup located in the side of engine door.
Brake fluid cup

Cleaning method of Water and contaminant in the air accumulator
Pull link at the bottom of air accumulator and drain the water and contaminant in the air reservoir
then reset the link.
Note . the two air reservoir are located at the rear frame and under the engine.
Drain valve


Replacing method of air dryer
Need replace air dryer when it cannot continue to suck water.
Note . the air dryer is located in the left side of back machine and under the hydraulic fan.
The replacing method of air dryer is same with oil filter replacing method.

1.3 hydraulic system

Hydraulic oil tank checking method
Lay the machine on the smooth ground and shut down the engine then observe the hydraulic oil
level.
When the level is lower than dipstick

middle guideline , at this time should fill
same type hydraulic oil.

1.4 implement , front and rear axle

Center bracket cylinder support lubricating point
Oil cup


Center shift lock rod washing and lubricating point
1. wash centershift lock rod

2. fill suitable grease into gauge hole.
Fill grease


Pull rod ball and ball socket lubricating
Fill grease


circle drive pinion lubricating
1. Clean contaminant
2. Fill suitable grease
Note . circle drive pinion is

located in the side of circle
and top of the blade.
Fill grease

Lubricating point on the top of the circle
Fill grease


Blade lifting cylinder bracket lubricating point
Lubricating position

Turbine box oil level checking method
1.Add gear oil when the gear oil level is lower than sight glass 1/3 position.
2.Clean the turbine box surface before adding oil.
3.The gear oil level should high than sight glass ½ position.
Note.
Make the turbine box is in horizontal
location when to check the oil level.
Sight glass


Turbine box oil replacing method
1.Remove drain plug and drain the gear oil.
2.after drain then clean the drain plug and
tighten.
3.Loose the filler plug and add gear oil to sight
glass ½ position.
4.Then clean the filler plug and tighten.
5.Start the machine and after operating circle
for 5 minutes then check the oil level if it is at
sight glass ½ position.
Drain plug


The lubrication point of blade
1.Blade cylinder bearing 2.Blade lifting link


Ripper lubrication point
1.Ripper cylinder 2.Ripper lifting link


Front axle lubrication point
1. Pin
2. Front wheel tilt pin
3. Front wheel tilt lever pin
4. Front wheel tilt cylinder pin
5. Front axle wiggle pin


1. Pin


1. Pin


1. Pin


1. Pin

1.5 the articulate between front and rear frame
Note: the filler is located under the cab on the left side of the machine.
Lubrication
position

1.6 electric system and cab

Maintenance of battery
Note . the battery provided from machine is

maintenance free ,so there is no need to check
the electrolyte level.
Check following list
1. Clean the top of battery
2. Clean the battery terminal and smear
lubrication；
3. Tighten battery mounting


Battery and battery terminal checking and replacement
1.turn start switch to OFF position

2.open the battery cover then turn the disconnect switch to OFF position
3.cutoff disconnect switch two sides cable
4.cutoff positive cable of battery
5.remove connecting wire of two battery and starter cable
6.Check if it is necessary to replace cable or battery
7.According to same procedure with opposed sequence to reconnect battery.


Fuse and reverse alarm
Fuse
It can protect electric system to damage due to circuit overload. If the fuse continue to be
damaged , need check circuit, resolve the troubleshooting then start the machine.
reverse alarm
It is located in the back of machine and lower corner of hydraulic fan.
Start machine and turn the shift control lever to reverse shift ,at this time reverse alarm need
alarm at once and continue until the shift control lever to neutral or forward gear.


Center electric control box
GPS relay
Charge indicator
relay
Neutral relay
Flasher relay
Reverse relay Shutdown relay


Cab new wind filter device and circulating wind filter device replacement
1.Remove filter device cover Filter device

cover
2.Remove filter device element
3.Install new filter device element
4.Install new filter device cover
Note. new wind filter device and circulating wind

filter device only can be replaced ,not be washed.
Filter device
cover


Window washer fluid reservoir
If the fluid level is low , need add fluid to

fluid reservoir.
Note.it is located in the lower right side of
cab.


Safety belt check and replace
Checking content.
1.Safety belt bracket
2.Safety belt lock
3 .whether the safety belt is damaged ,if
damaged , need replace immediately.
Note .
Before operating machine , must check safety belt , if find some damaged parts , must
replace then operate machine .
In the installation of three years as of the date to replace the safety belt.

Chapter 2: adjustment of machine
2.1 Blade
Right adjust
1.Turn the blade to the right and down to

ground
2.Release the four bolts of piston rod ear
support
3.Adjust the piston ear to the (two) position.
4.spin-on four retainer bolts and tighten
according to required torque.
two one

2.1 Blade
Left adjust
1.Turn the blade to the left and down to

ground
2.Release the four bolts of piston rod ear
support
3.Adjust the piston ear to the (two)
position.
4.spin-on four retainer bolts and tighten
according to required torque. (one) (two)

2.1 Blade
Blade track clearance check and adjust Orifice plate
If the clearance of wear block is big ,need replace

new wear block .following is the method.
1.remove two orifice plate of wear block
2.Move blade and let wear block back out , replace
new wear block then install bolts of orifice plate and
tighten
3. After replacing the blade should be freely.
耐磨块位置
Wear block

2.2 blade circle

Blade circle clearance check and adjust
1.Rotate the blade and install two C type clamps in

the position where the blade and frame form 90
degree angle.
2.The circle fixed with tongue by C type clamp , wear
plate contact with top of circle and bottom of tongue. C type clamp
3.Put the blade down to ground then shut down
machine.
4.Measure the clearance A between circle top surface
and tongue bottom surface , if the distance smaller
than 1.5cm,need replace wear plate three.
5.if the wear plate three can not whole contact with
circle surface ,need replace the wear plate three.
Wear plate

2.2 blade circle

5.Tighten (four ,five , six)bolts of following photo , ensure that the whole wear plate is located on
the lining plate of circle position.
(four) (five) (six) Wear plate (three)

2.2 blade circle
6.Measure the clearance (B) between bottom of

circle (1) and top of wear plate (7),keep max
clearance be 0.5mm,use the method that add or
reduce washer(8) to hold appropriate clearance,
according to the requirements to add or remove
washer.
7.tighten the bolts(4)(5)(6).
8.After lining plate was adjusted , check the

clearance if it is suitable.
Note . finished the adjustment ,the circle should

not be blocked and need rotate smoothly.

2.2 blade circle

the clearance between circle pinion and circle check and adjust
1.Keep the circle 90 degree position with frame and down to ground , drive the machine slowly ,put
small load to plate of front circle and wear plate of circle and shut down engine.
2.Measure the clearance (X) between pinion bottom flange (10) and circle inner surface (1) ,if it is
smaller than 49.5～ 52.5mm, should adjust .
3.Loose the lining plate bolts (4)(5)(6)(11).
4.Perodiclly Adjust the lining plate on the front of circle, turn the bolt (12) to inside or outside ,make
the spacing be 49.5～52.5mm ,and adjust another circle lining plate.

2.2 blade circle
the clearance between circle pinion and circle check and adjust
5. if the wear plate is wear , should replace.

6. tighten lining bolts(4)(5)(6)(11).
7. thorough circle lining plate should contacted with circle ,no gap.
8. When finish the pinion clearance and thorough circle lining plate have contact with circle ,then
measure the spacing between each wear plate and circle ,the max gap is 0.8mm.
9. tighten bolts (4)(5)(6) with475±60 N·m .
10. Tighten all locked bolts (11) with 200±30 N·m.

2.3 blade lifting cylinder bracket
Check ,adjust and replace blade lifting cylinder bracket
1、turn the blade with frame make 90 degree and down to

ground
2.Operate blade lifting cylinder and observe bracket , if the
bracket move and blade do not move , this situation need
adjust.
3.Remove bolt (2) and take cover(1)
4. Remove one washer from one side ,make the gap reduce
5. install the cover and tighten the bolts
6. Observe the bracket action , if find bracket move , need
readjust.
Note . (1) (2)
if need remove two washers , must remove one from two
sides.

2.4 center frame cylinder bracket
Center bracket cylinder support check , adjust and adjust
1.Blade with frame form 90 degree and down to ground.

2.Operate center bracket cylinder , and observe the bracket ,
if the support move and blade do not move ,this situation
need adjust.
3、Remove bolt (2) and take cover(1).
4、 Remove one washer from one side ,make the gap (2)
reduce.
Note .
if need remove two washers , must remove one from two (1)
sides.
5. install the cover and tighten the bolts
6. Observe the bracket action , if find bracket move , need
readjust.


Check adjust and replace drawbar ball and socket clearance
Check
1.Keep blade 90 degree with frame and
then down to ground , when the load is
small between drawbar ball and bracket ,
at present rear the machine slowly and
shut down the machine and engine. cover（3）
2、at present measure the end clearance
between ball and cover , should be
0.6±0.2mm.
ball（2）


Adjust
Fix drawbar and circle
1.Remove the bolt on the drawbar（1）,move back
drawbar or move front the machine.
2、remove the fixture bolt (7),and adapter(6) .
3、remove or install shim(4) ,make the end
clearance be 0.6±0.2mm；
4、tight drawbar adapter (6) and cover （3）， with
bolt（7）,rotate group ，should be free and smooth.

Replace
bolt(1)
1.Check the torque between drawbar and fixed bolt of
ball ,should be 500±65N·m；
2、install the drawbar on frame and then tighten bolt
(1) ,make the torque up to 950±50 N·m；
bolt(1)
Fixed bolt(5)

Chapter 3. Oil for maintenance- 919,921 with Stage II engine



Chapter 3. Oil for maintenance- 919,921 with Stage III engine



Chapter 3. Oil for maintenance- 915 with Stage II engine



Chapter 3. Oil for maintenance- 915 with Stage III engine









Important tips
The oil type and oil change interval
are used by the current model. For
accurate data, please refer to the
maintenance manual of each model or
contact the TIS team

THE END
THANKS
© 2014 Caterpillar (Qingzhou) Ltd. All Rights Reserved. SEM and its respective logos
and trade dress as well as the corporate and product identity used herein are
trademarks of Caterpillar (Qingzhou) Ltd. and may not be used without permission

PM MG915,917,919,921,922

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Preventive maintenance-MG915，917，919，921，922

Caterpillar: Confidential Green

Caterpillar: Confidential Green

Caterpillar: Confidential Green

Caterpillar: Confidential Green

Normal status Maintenance status

Caterpillar: Confidential Green

Replacing procedure： Clean housing

Caterpillar: Confidential Green

Coolant filter remove Smear oil

Caterpillar: Confidential Green

Middle level of sight glass

Caterpillar: Confidential Green

Caterpillar: Confidential Green

Caterpillar: Confidential Green

Caterpillar: Confidential Green

The remove & Install method is same with stage II engine.

Primary Secondary Drain water Triple

Caterpillar: Confidential Green

Filter element o ring

Caterpillar: Confidential Green

1.1 Engine part

Drain oil bolt is located on the right side of machine.

Caterpillar: Confidential Green

Caterpillar: Confidential Green

1.1 Engine part

Top line Bottom line

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Caterpillar: Confidential Green

1.1 Engine part

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1.2 transmission and brake system

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1.2 transmission and brake system remove

1. Clean around of filter

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1.2 transmission and brake system

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1.2 transmission and brake system

oil level plug

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1.2 transmission and brake system

Operating procedure： oil level plug and filler plug

1.Lay the machine on the 20 degree slope and

Drain oil plug

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1.2 transmission and brake system

Main reducer oil level hole

Caterpillar: Confidential Green

Remove drain oil plug and make the oil flow to

Main and planetary reducer group need fill

Main reducer filler hole

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1.2 transmission and brake system

Brake fluid cup

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Caterpillar: Confidential Green

1.2 transmission and brake system

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1.3 hydraulic system

When the level is lower than dipstick

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1.4 implement , front and rear axle