Maintenance Intervals - Sebu8593-01 m (Tra)

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MAINTENANCE INTERVALSOperation and Maintenance Manual Excerpt

SEBU8593-01October 2011

Operation andMaintenanceManualD9T Track-Type TractorTWG1-Up (D9T)

SAFETY.CAT.COM

128 SEBU8593-01Maintenance SectionCooling System Specifications

Maintenance Section

Cooling SystemSpecifications

i02011932

Model Specific CoolantInformationSMCS Code: 1000

NOTICEAdding coolant to an overheated engine could result indamage to the engine. Allow the engine to cool beforeadding coolant.

If the machine is to be stored in, or shipped to, an areawith freezing temperatures, the cooling system mustbe protected to the lowest outside (ambient) temper-ature.

The engine cooling system is normally protect-ed to a minimum of−29°C (−20°F) with CaterpillarAntifreeze, when shipped from the factory unlessspecial requirements are defined.

NOTICEFrequently check the specific gravity of the coolant toensure proper freeze protection and anti-boil protec-tion.

NOTICENever use water alone as a coolant. Water alone iscorrosive at engine operating temperatures and doesnot provide adequate anti-boil protection.

NOTICEAll Caterpillar diesel engines equipped with air-to-airaftercooling (ATAAC) require a minimum of 30 percentglycol to prevent water pump cavitation.

Extended Life Coolant (ELC) is used at the factory forthe D9TTrack-Type Tractor .

Reference: Refer to Service Manual, SEBU6250,“Caterpillar Machine Fluids Recommendations”,“Cat Extended Life Coolant (ELC)”. See the section“ELC Cooling System Maintenance” in order tomaintain your cooling system. However, maintainingan ELC cooling system is preferred. Also, see thetopics“Coolant Recommendations” and “S·O·SCoolant Analysis”.

The following problems may indicate a need to checkthe cooling system:

• Engine overheating

• A strong, unusual odor from the coolant

• Contamination of the cooling system

• A change in the color of the coolant

• Foaming within the radiator

Air pockets can form in the cooling system if thecooling system is filled at a rate that is greater than20 L (5 US gal ) per minute.

After you drain the cooling system and after you refillthe cooling system, operate the engine. Operatethe engine without the radiator cap until the coolantreaches normal operating temperature and thecoolant level stabilizes. Make sure that the coolant ismaintained to the proper level.

NOTICENever operate an engine without water temperatureregulators in the cooling system. Water temperatureregulators help to maintain the engine coolant at theproper operating temperature. Cooling system prob-lems can develop without water temperature regula-tors.

For more detailed information, refer to the followingpublication: Special Publication, REHS1063, “SpecialInstruction - Know Your Track-Type Tractor CoolingSystem”.

Many engine failures are related to the coolingsystem. Cooling system failures include the followingproblems: overheating, leakage of the water pump,plugged radiators, and cylinder liner pitting. Thesefailures could be avoided with proper cooling systemmaintenance. Maintenance of the engine coolant isimportant to the engine life and to the performance.Maintaining the quality of the engine's coolant is asimportant as maintaining the quality of the engine'sfuel and lubricating oil.

Coolant is normally composed of three elements:

• Water is used for transferring heat from the engineto the atmosphere.

• Additives are used for corrosion protection.

• Glycol is used for anti-boil protection and antifreezeprotection.

SEBU8593-01 129Maintenance Section

Lubricant Viscosities and Refill Capacities

Lubricant Viscosities andRefill Capacities

i04561327

Lubricant Viscosities(Fluids Recommendations)SMCS Code: 7581

General Information for LubricantsWhen you are operating the machine in temperaturesbelow −20°C (−4°F), refer to Special Publication,SEBU5898, “Cold Weather Recommendations”. Thispublication is available from your Cat dealer.

For cold-weather applications where transmissionoil SAE 0W-20 is recommended, Cat Cold WeatherTDTO is recommended.

Refer to the “Lubricant Information” section in thelatest revision of the Special Publication, SEBU6250,“Caterpillar Machine Fluids Recommendations” for alist of Cat engine oils and for detailed information. Thismanual may be found on the Web at Safety.Cat.com.

The footnotes are a key part of the tables. Read ALLfootnotes that pertain to the machine compartmentin question.

Selecting the ViscosityIn order to select the proper oil for each machinecompartment, refer to the “Lubricant Viscosity forAmbient Temperature” table. Use the oil type AND oilviscosity for the specific compartment at the properambient temperature.

The proper oil viscosity grade is determined bythe minimum ambient temperature (the air in theimmediate vicinity of the machine). Measure thetemperature when the machine is started and whilethe machine is operated. In order to determinethe proper oil viscosity grade, refer to the “Min”column in the table. This information reflects thecoldest ambient temperature condition for startinga cold machine and for operating a cold machine.Refer to the “Max” column in the table for operatingthe machine at the highest temperature that isanticipated. Unless specified otherwise in the“Lubricant Viscosities for Ambient Temperatures”tables, use the highest oil viscosity that is allowed forthe ambient temperature.

Machines that are operated continuously shoulduse oils that have the higher oil viscosity in the finaldrives and in the differentials. The oils that have thehigher oil viscosity will maintain the highest possibleoil film thickness. Refer to “General Information forLubricants” article, “Lubricant Viscosities” tables, andany associated footnotes. Consult your Cat dealer ifadditional information is needed.

NOTICENot following the recommendations found in this man-ual can lead to reduced performance and compart-ment failure.

Engine OilCat oils have been developed and tested in order toprovide the full performance and life that has beendesigned and built into Cat engines.

Cat DEO-ULS multigrade and Cat DEO multigradeoils are formulated with the correct amounts ofdetergents, dispersants, and alkalinity in order toprovide superior performance in Cat diesel engineswhere recommended for use.

130 SEBU8593-01Maintenance SectionLubricant Viscosities and Refill Capacities

Table 20

Lubricant Viscosities for Ambient Temperatures

°C °FCompartment or System Oil Type and Performance

Requirements Oil ViscositiesMin Max Min Max

Cat DEO-ULS Cold Weather SAE 0W-40 −40 40 −40 104

Cat DEO-ULS SYNCat DEO SYN SAE 5W-40 −30 50 −22 122

Cat DEO-ULSCat DEO SAE 10W-30 −18 40 0 104

Engine Crankcase

Cat DEO-ULSCat DEO SAE 15W-40 −9.5 50 15 122

When fuels of sulfur level of 0.1 percent (1000 ppm)or higher are used, Cat DEO-ULS may be used ifS·O·S oil analysis program is followed. Base the oilchange interval on the oil analysis.

Hydraulic SystemsRefer to the “Lubricant Information” section in thelatest revision of the Special Publication, SEBU6250,“Caterpillar Machine Fluids Recommendations” fordetailed information. This manual may be found onthe Web at Safety.Cat.com.

The following are the preferred oils for use in mostCat machine hydraulic systems:

• Cat HYDO Advanced 10 SAE 10W

• Cat HYDO Advanced 30 SAE 30W

• Cat BIO HYDO Advanced

Cat HYDO Advanced fluids have a 50% increasein the standard oil drain interval for machinehydraulic systems (3000 hours versus 2000 hours)over second and third choice oils when you follow themaintenance interval schedule for oil filter changesand for oil sampling that is stated in the Operationand Maintenance Manual for your particular machine.6000 hour oil drain intervals are possible when usingS·O·S Services oil analysis. Consult your Cat dealerfor details. When switching to Cat HYDO Advancedfluids, cross contamination with the previous oilshould be kept to less than 10%.

Second choice oils are listed below.

• Cat MTO

• Cat DEO

• Cat DEO-ULS

• Cat TDTO

• Cat TDTO Cold Weather

• Cat TDTO-TMS

• Cat DEO-ULS SYN

• Cat DEO SYN

• Cat DEO-ULS Cold Weather



Table 21

Lubricant Viscosities for Ambient Temperatures

°C °FCompartment or System Oil Type and Performance

Requirements Oil ViscositiesMin Max Min Max

Cat HYDO Advanced 10Cat TDTO SAE 10W −20 40 −4 104

Cat HYDO Advanced 30Cat TDTO SAE 30 0 50 32 122

Cat BIO HYDO Advanced “ISO 46”Multi-Grade −30 45 −22 113

Cat MTOCat DEO-ULSCat DEO

SAE10W-30 −20 40 −4 104

Cat DEO-ULSCat DEO SAE15W-40 −15 50 5 122

Cat TDTO-TMS Multi-Grade −15 50 5 122

Cat DEO-ULS SYNCat DEO SYN SAE 5W-40 −25 40 −13 104

Cat DEO-ULS Cold Weather SAE0W-40 −40 40 −40 104

Hydraulic System

Cat TDTO Cold Weather SAE 0W-20 −40 40 −40 104

Transmission and Final DriveRefer to the “Lubricant Information” section in thelatest revision of the Special Publication, SEBU6250,“Caterpillar Machine Fluids Recommendations” fordetailed information. This manual may be found onthe Web at Safety.Cat.com.

Where recommended for use, Cat FDAO SYN CatFDAO or commercial oil that meets Cat FD-1 are thepreferred oil types to maximize gear life and bearinglife. Do not use Cat FDAO, Cat FDAO SYN, or CatFD-1 in compartments containing clutches and/orbrakes. Cat TDTO, Cat TDTO-TMS, or commercialoil that meets Cat TO-4 oil types must be used inany compartment containing friction material unlessspecified otherwise by Caterpillar.

For the Final Drives in severe usage or in continuousoperations, WARM-UP is required. Exercise the finaldrives for several minutes with the engine at a partialthrottle in order to warm up the oil prior to productionoperation.

When you are operating the machine in temperaturesbelow −20°C (−4°F), refer to Special Publication,SEBU5898, “Cold Weather Recommendations”. Thispublication is available from your Cat dealer.


Table 22

Track Type Tractors Lubricant Viscosities for Ambient Temperatures

°C °FCompartment orSystem Application

Oil Type andPerformanceRequirements

Oil ViscositiesMin Max Min Max

SAE 0W-20 −40 10 −40 50

SAE 10W −20 10 −4 50

SAE 30 0 35 32 95

SAE 50 10 50 50 122

Power ShiftTransmissions Normal

Cat TDTOCat TDTO-TMSCat Cold Weather

TDTOCat TO-4, Cat TO-4M

Cat TDTO-TMS −20 43 −4 110

SAE 60 −7 50 19 122

SAE 50 −15 32 5 90

SAE 30 −25 15 −13 59

Cat TDTO-TMS −35 15 −31 59

ModerateUsage orIntermittentOperation

Cat FDAOCat FDAO SYNCat TDTO

Cat TDTO-TMSCat FD-1, Cat TO-4,

Cat TO-4MCat FDAOSYN −15 50 5 122

SAE 60 −25 50 −13 122

SAE 50 −33 14 −27 58

SAE 30 −40 0 −40 32

Cat TDTO-TMS −40 0 −40 32

Final Drive

SevereUsage orContinuousOperation(MultipleShifts)

Cat FDAOCat FDAO SYNCat TDTO

Cat TDTO-TMSCat FD-1, Cat TO-4,

Cat TO-4MCat FDAOSYN −33 50 -27 122



Track Type Tractors Special ApplicationsTable 23

Special Track Type Tractors Lubricant Viscosities for Ambient Temperatures

°C °FCompartment orSystem Application

Oil Type andPerformanceRequirements

Oil ViscositiesMin Max Min Max

SAE 75W-90 −30 40 −22 104

SAE 75W-140 −30 45 −22 113

SAE 80W-90 −20 40 −4 104Bogie Cartridge Pinsand Track Pins Normal

Cat GO (Gear Oil)Cat Synthetic GOAPI GL-5 gear oil

SAE 85W-140 −10 50 14 122

SAE 90 0 40 32 104

SAE 0W-20 −40 10 −40 50

SAE 10W −20 10 −4 50

SAE 30 0 43 32 110

Winches (hydraulicdrive) Normal

Cat TDTOCat TDTO-TMS

Cat TO-4, Cat TO-4M

Cat TDTO-TMS −10 35 14 95

SAE 0W-20 −40 0 v40 32

SAE 5W-20 −35 0 −31 32

SAE 10W −30 0 −22 32

SAE 30 −20 25 −4 77

SAE 40 −10 40 14 104

SAE 50 0 50 32 122

Track Roller FrameRecoil Spring PivotShaft Bearings

Normal

Cat TDTOCat TDTO-TMSCat Cold Weather

TDTOCat TO-4, Cat TO-4M

Cat TDTO-TMS −25 25 −13 77

SAE 30 −20 25 −4 77

SAE 5W-40 −35 40 −31 104Track Idlers andTrack Rollers Normal

Cat DEO (singlegrade)

Cat DEO SYNCat DEO-ULS SYN

Cat ECF-1-aCat ECF-2Cat ECF-3API CF

SAE 0W40 −40 40 −40 104

Special Lubricants

Grease

In order to use a non-Cat grease, the supplier mustcertify that the lubricant is compatible with Catgrease.

Each pin joint should be flushed with the new grease.Ensure that all old grease is removed. Failure to meetthis requirement may lead to failure of a pin joint.


Table 24

Recommended Grease

°C °FCompartment or System GreaseType NLGI Grade

Min Max Min Max

Cat Advanced 3Moly NLGI Grade 2 −20 40 −4 104

NLGI Grade 2 −30 50 −22 122

NLGI Grade 1 −35 40 −31 104Cat Ultra 5Moly

NLGI Grade 0 −40 35 −40 95

Cat Arctic Platinum NLGI Grade 0 −50 20 −58 68

External Lubrication PointsIncluding Equalizer Bar

End Pin Joints

Cat Desert Gold NLGI Grade 2 −20 60 −4 140

Diesel Fuel RecommendationsDiesel fuel must meet “Caterpillar Specificationfor Distillate Fuel” and the latest versions of“ASTM D975” or “EN 590” in order to ensureoptimum engine performance. Refer to SpecialPublication, SEBU6250, “Caterpillar Machine FluidsRecommendations” for the latest fuel information andfor Cat fuel specification. This manual may be foundon the Web at Safety.Cat.com.

The preferred fuels are distillate fuels. Thesefuels are commonly called diesel fuel, furnace oil,gas oil, or kerosene. These fuels must meet the“Caterpillar Specification for Distillate Diesel Fuelfor Off-Highway Diesel Engines”. Diesel Fuels thatmeet the Caterpillar specification will help providemaximum engine service life and performance.

Misfueling with fuels of high sulfur level can havethe following negative effects:

• Reduce engine efficiency and durability

• Increase the wear

• Increase the corrosion

• Increase the deposits

• Lower fuel economy

• Shorten the time period between oil drain intervals(more frequent oil drain intervals)

• Increase overall operating costs

• Negatively impact engine emissions

Failures that result from the use of improper fuelsare not Caterpillar factory defects. Therefore thecost of repairs would not be covered by a Caterpillarwarranty.

Caterpillar does not require the use of ULSD in offroad and machine applications that are not Tier4/Stage IIIB certified engines. ULSD is not requiredin engines that are not equipped with after treatmentdevices.

Follow operating instructions and fuel tank inletlabels, if available, in order to ensure that the correctfuels are used.

Refer to Special Publication, SEBU6250, “CaterpillarMachine Fluids Recommendations” for more detailsabout fuels and lubricants. This manual may be foundon the Web at Safety.Cat.com.

Fuel AdditivesCat Diesel Fuel Conditioner and Cat Fuel SystemCleaner are available for use when needed. Theseproducts are applicable to diesel and biodiesel fuels.Consult your Cat dealer for availability.

BiodieselBiodiesel is a fuel that can be made from variousrenewable resources that include vegetable oils,animal fat, and waste cooking oil. Soybean oil andrapeseed oil are the primary vegetable oil sources.In order to use any of these oils or fats as fuel, theoils or fats are chemically processed (esterified). Thewater and contaminants are removed.

U.S. distillate diesel fuel specification “ASTMD975-09a” includes up to B5 (5 percent) biodiesel.Currently, any diesel fuel in the U.S. may contain upto B5 biodiesel fuel.

European distillate diesel fuel specification “EN 590”includes up to B5 (5 percent) and in some regions upto B7 (7 percent) biodiesel. Any diesel fuel in Europemay contain up to B5 or in some regions up to B7biodiesel fuel.



Note: Up to B20 biodiesel blend level is acceptablefor use in this Track-Type Tractor engine.

When biodiesel fuel is used, certain guidelines mustbe followed. Biodiesel fuel can influence the engineoil, aftertreatment devices, non-metallic, fuel systemcomponents, and others. Biodiesel fuel has limitedstorage life and has limited oxidation stability. Followthe guidelines and requirements for engines thatare seasonally operated and for standby powergeneration engines.

In order to reduce the risks associated with the use ofbiodiesel, the final biodiesel blend and the biodieselfuel used must meet specific blending requirements.

All the guidelines and requirements are provided inthe latest revision of Special Publication, SEBU6250,“Caterpillar Machine Fluids Recommendations”. Thismanual may be found on the Web at Safety.Cat.com.

Coolant InformationThe information provided in this “CoolantRecommendation” section should be used with the“Lubricants Information” provided in the latest revisionof Special Publication, SEBU6250, “CaterpillarMachine Fluids Recommendations”. This manualmay be found on the Web at Safety.Cat.com.

Additional information about the cooling system onthis machine may be found in the latest revision ofSpecial Publication, SEBD0518, “Know Your CoolingSystem”.

The following two types of coolants may be used inCat diesel engines:

Preferred – Cat ELC (Extended Life Coolant)

Acceptable – Cat DEAC (Diesel EngineAntifreeze/Coolant)

NOTICENever use water alone as a coolant. Water alone iscorrosive at engine operating temperatures. In addi-tion, water alone does not provide adequate protec-tion against boiling or freezing.

i04560794

Capacities (Refill)SMCS Code: 7560

Table 25

APPROXIMATE REFILL CAPACITIES

Compartment orSystem

Liters USGallons

ImperialGallons

Cooling System 101 26.7 22.2

Fuel Tank 889 235 195.6

Engine Crankcaseand filter

34 9 7.5

Power Train Oil 164 43.3 36.1

Hydraulic Tank Oil(Only)

89 23.5 19.6

Each Final Drive 15 3.9 3.3

Roller Frames (EachCompartment)

45 11.9 9.9

Pivot Shaft 30 7.9 6.6

Note: You should increase the quantity of oil in thepower train whenever you operate the machineon severe slopes. The quantity of oil in the powertrain can be increased up to 10 percent. When youoperate with this increased oil quantity, prolongedoperation in some machine positions can cause highpower train oil temperatures. Remove this excessiveoil quantity after your work on severe slopes hasbeen completed.

Note: For severe slope operation, engine oil shouldbe maintained on the full mark. The engine shouldnever be overfilled with oil.


Ecology DrainsTable 26

Ecology Drain (Components)

Location (Drain) Needed Component

Coolant12.7 mm (0.5 inch)pipe with 1/2-14 NPTHthread

Transmission12.7 mm (0.5 inch)pipe with 1/2-14 NPTHthread

Torque Converter12.7 mm (0.5 inch)pipe with 1/2-14 NPTHthread

Engine Oil 25.4 mm (1 inch) pipe with1-11 1/2 NPTH thread

Hydraulic Tank

126-7914 Oil DrainCouplingor25.4 mm (1 inch) pipe with1-11 1/2 NPTH thread

Bevel Gear Case

4C-8563 Oil DrainCouplingor25.4 mm (1 inch) pipe with1-11 1/2 NPTH thread

i04311449

S·O·S InformationSMCS Code: 7542

S·O·S Services is a highly recommended process forCat customers to use in order to minimize owningand operating cost. Customers provide oil samples,coolant samples, and other machine information.The dealer uses the data in order to provide thecustomer with recommendations for management ofthe equipment. In addition, S·O·S Services can helpdetermine the cause of an existing product problem.

Refer to Special Publication, SEBU6250, “CaterpillarMachine Fluid Recommendations” for detailedinformation concerning S·O·S Services.

Refer to the Operation and Maintenance Manual,“Maintenance Interval Schedule” for a specificsampling location and a service hour maintenanceinterval.

Consult your Cat dealer for complete information andassistance in establishing an S·O·S program for yourequipment.

SEBU8593-01 137Maintenance SectionMaintenance Support

Maintenance Supporti03636245

Welding on Machines andEngines with ElectronicControlsSMCS Code: 1000; 6700; 7000

Do not weld on any protective structure. If it isnecessary to repair a protective structure, contactyour Caterpillar dealer.

Proper welding procedures are necessary in order toavoid damage to the electronic controls and to thebearings. When possible, remove the componentthat must be welded from the machine or the engineand then weld the component. If you must weld nearan electronic control on the machine or the engine,temporarily remove the electronic control in order toprevent heat related damage. The following stepsshould be followed in order to weld on a machine oran engine with electronic controls.

1. Turn off the engine. Place the engine start switchin the OFF position.

2. If equipped, turn the battery disconnect switch tothe OFF position. If there is no battery disconnectswitch, remove the negative battery cable at thebattery.

NOTICEDo NOT use electrical components (ECM or sensors)or electronic component grounding points for ground-ing the welder.

3. Clamp the ground cable from the welder to thecomponent that will be welded. Place the clampas close as possible to the weld. Make sure thatthe electrical path from the ground cable to thecomponent does not go through any bearing. Usethis procedure in order to reduce the possibility ofdamage to the following components:

• Bearings of the drive train

• Hydraulic components

• Electrical components

• Other components of the machine

4. Protect any wiring harnesses and componentsfrom the debris and the spatter which is createdfrom welding.

5. Use standard welding procedures in order to weldthe materials together.

138 SEBU8593-01Maintenance SectionMaintenance Interval Schedule

i04549839

Maintenance Interval ScheduleSMCS Code: 7000

Ensure that all safety information, warnings, andinstructions are read and understood before anyoperation or any maintenance procedures areperformed.

The user is responsible for the performance ofmaintenance. All adjustments, the use of properlubricants, fluids, filters, and the replacement ofcomponents due to normal wear and aging areincluded. Failure to adhere to proper maintenanceintervals and procedures may result in diminishedperformance of the product and/or accelerated wearof components.

Use mileage, fuel consumption, service hours, orcalendar time, WHICH EVER OCCURS FIRST,in order to determine the maintenance intervals.Products that operate in severe operating conditionsmay require more frequent maintenance. Refer to themaintenance procedure for any other exceptions thatmay change the maintenance intervals.

Note: Before each consecutive interval is performed,all maintenance from the previous interval must beperformed.

Note: If Cat HYDO Advanced hydraulic oils are used,the hydraulic oil change interval is extended to 3000hours. S·O·S services may extend the oil changeeven longer. Consult your Cat dealer for details.

When Required

Battery, Battery Cable or Battery Disconnect Switch -Replace ............................................................. 140Camera - Clean/Adjust ....................................... 144Cooler Cores and A/C Condenser - Clean ......... 145Cutting Edges and End Bits - Inspect/Replace ... 154Engine Air Filter Primary Element - Clean/Replace ............................................................. 155Engine Air Filter Secondary Element - Replace .. 156Engine Air Precleaner - Clean ............................ 157Ether Starting Aid Cylinder - Replace ................. 167Fuel System - Prime ........................................... 172Fuses and Circuit Breakers - Replace/Reset ...... 177Hydraulic System Filter Screens - Clean ............ 178Oil Filter - Inspect ................................................ 185Power Train Scavenge Screen - Clean ............... 190Radiator Core - Clean ......................................... 196Radiator Pressure Cap - Clean/Replace ............ 197Ripper Tip and Shank Protector - Inspect/Replace ............................................................. 199Torque Converter Scavenge Screen - Clean ...... 202Winch Wire Rope - Install ................................... 208Window Washer Reservoir - Fill .......................... 208Window Wipers - Inspect/Replace ...................... 209

Windows - Clean ................................................. 209

Every 10 Service Hours or Daily

Backup Alarm - Test ............................................ 140Braking System - Test ......................................... 142Cab Filter (Fresh Air) - Clean/Inspect/Replace ... 143Cooling System Coolant Level - Check .............. 151Engine Oil Level - Check .................................... 157Fuel System Primary Filter (Water Separator) -Drain ................................................................. 172Fuel Tank Water and Sediment - Drain ............... 176Horn - Test .......................................................... 178Hydraulic System Oil Level - Check .................. 182Indicators and Gauges - Test .............................. 183Pivot Shaft Oil Level - Check .............................. 185Power Train System Oil Level - Check ............... 195Seat Belt - Inspect .............................................. 200Walk-Around Inspection ...................................... 206

Every 50 Service Hours

Bulldozer Tilt Brace and Tilt Cylinders -Lubricate ........................................................... 143Cab Filter (Recirculation) - Clean/Inspect/Replace ............................................................. 144Equalizer Bar End Pins - Lubricate ..................... 165Lift Cylinder Yoke Bearings - Lubricate ............... 184Ripper Linkage and Cylinder Bearings -Lubricate ........................................................... 199Track Pins - Inspect ............................................ 204


Belt - Inspect/Adjust/Replace .............................. 141Engine Oil Sample - Obtain ................................ 158Engine Oil and Filter - Change ........................... 159Final Drive Oil Level - Check .............................. 168Track - Check/Adjust ........................................... 203Winch Fairlead Rollers - Lubricate ...................... 206Winch Oil Level - Check ..................................... 206

Initial 500 Hours (for New Systems, RefilledSystems, and Converted Systems)

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 151Electronic Unit Injector - Inspect/Adjust .............. 154Engine Valve Lash - Check/Adjust ...................... 162Engine Valve Rotators - Inspect ......................... 162Winch Oil and Breather - Change/Clean ............ 207


Final Drive Oil Sample - Obtain .......................... 168Final Drive Seal Guard - Inspect/Clean .............. 169Fuel System Primary Filter - Clean/Replace ....... 173Fuel System Secondary Filter - Replace ............ 174Fuel Tank Cap Filter and Strainer -Replace/Clean .................................................. 176Hydraulic System Oil Filter - Replace ................. 181Hydraulic System Oil Sample - Obtain ............... 183


Maintenance Interval Schedule

Power Train Breather - Clean ............................. 186Power Train Oil Filters - Replace ........................ 189Power Train System Oil Sample - Obtain ........... 195Recoil Spring Compartment Oil Level - Check ... 197


Steering Charge Filter - Replace ........................ 201

Every 1000 Service Hours or 6 Months

Battery - Inspect .................................................. 140Power Train Oil - Change ................................... 186Power Train System Oil And Screens -Change/Clean ................................................... 191Rollover Protective Structure (ROPS) - Inspect .. 200Winch Oil and Breather - Change/Clean ............ 207

Every 2000 Service Hours or 1 Year

Crankshaft Vibration Damper - Inspect ............... 152Engine Mounts - Inspect ..................................... 157Equalizer Bar - Inspect ....................................... 163Final Drive Oil - Change ..................................... 167Final Drive Seal Guard Packing - Replace ......... 170Hydraulic System Oil - Change ........................... 180Track Roller Frame - Inspect .............................. 205Track Roller Frame Guides - Inspect .................. 205

Every Year

Engine Air Filter Primary Element - Replace ...... 156Engine Air Filter Secondary Element - Replace .. 156

Every 2 Years

Refrigerant Dryer - Replace ................................ 198

Every 3 Years

Seat Belt - Replace ............................................. 200


Electronic Unit Injector - Inspect/Adjust .............. 154Engine Valve Lash - Check/Adjust ...................... 162Engine Valve Rotators - Inspect ......................... 162

Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .. 150Cooling System Water Temperature Regulator -Replace ............................................................. 152

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 148

140 SEBU8593-01Maintenance SectionBackup Alarm - Test

i04354571

Backup Alarm - TestSMCS Code: 7406-081

In order to test the alarm for proper functioning, turnthe engine start switch to the ON position.

g02509537Illustration 172Direction control switch located on steering control

Apply the service brake. Release the parking brake.Move the direction control switch to the REVERSEposition.

The backup alarm should start to sound immediately.The backup alarm will continue to sound until thedirection control switch is moved to the NEUTRALposition or to the FORWARD position.

g02509637Illustration 173Location of backup alarm

The backup alarm is on the rear of the machine.

The nonadjustable backup alarm is set at theappropriate sound level when the machine is shippedfrom the factory.

i04355233

Battery - InspectSMCS Code: 1401-040

g02510279Illustration 174Left-hand battery and window washer fluid reservoir compartment(Left-hand guard rail assembly removed for illustration)

(1) Battery terminals and terminal covers(2) Compartment access cover (in opened position)(3) Retainers

Note: Perform the following procedures at every1000 hour interval. Check the following areas moreoften, as required.

1. Open the battery access cover (2). The batteryaccess cover is on the left side of the machinenext to the operator compartment.

2. Tighten retainers (3) on the batteries at every1000 hour interval.

3. Clean the top of the batteries with a clean cloth.Keep terminals (1) clean and coat the terminalswith petroleum jelly. Install the terminal coversafter you coat the terminals.

1. Close the battery access cover.

i04355610

Battery, Battery Cable orBattery Disconnect Switch -ReplaceSMCS Code: 1401-510; 1402-510; 1411-510

1. Turn the engine start switch key to the OFFposition. Turn all of the switches to the OFFposition.


Belt - Inspect/Adjust/Replace

g02510540Illustration 175

2. Locate the battery disconnect switch. The batterydisconnect switch is contained in the ground levelservice center which is located at the front ofthe left-hand fender. Turn the battery disconnectswitch to the OFF position. Remove the key.

3. Disconnect the battery cable at the batterydisconnect switch.

4. Disconnect the negative battery cable at thebattery.

5. Replace the disconnect switch, the battery cables,or the batteries, as required.

6. Connect the negative battery cable at the battery.

7. Connect the negative battery cable at the batterydisconnect switch.

8. Install the key and turn the battery disconnectswitch to the ON position.

Battery RecycleAlways recycle a battery. Never discard a battery.

Always return used batteries to one of the followinglocations:

• A battery supplier

• An authorized battery collection facility

• Recycling facility

i04355655

Belt - Inspect/Adjust/ReplaceSMCS Code: 1357-025; 1357-040; 1357-510

This engine is equipped with a serpentine beltthat drives the alternator and the air conditionercompressor.

The belt tightener on this engine automaticallyadjusts the serpentine belt to the correct tension.

Inspect1. Park the machine on level ground. Lower thedozer blade to the ground. Move the transmissioncontrol to the NEUTRAL position and engage theparking brake. Shut off the engine.

2. Turn the battery disconnect switch to the OFFposition.

3. Open both the right-hand and left-hand engineaccess doors.


Engine front left view(1) Belt tensioner(2) Idler pulley (grooved)(3) Idler pulleys (smooth)(4) Alternator pulley(5) Air conditioner compressor pulley(6) Serpentine belt(7) Crankshaft drive pulley (hidden from view behind crankshaft

damper)

4. Inspect the condition of serpentine belt (6).Replace the serpentine belt if excessive wear orcracking has occurred. Wear due to belt slippageindicates that the belt tensioner possibly needsto be replaced.

142 SEBU8593-01Maintenance SectionBraking System - Test

5. Close both the right-hand and left-hand engineaccess doors.

6. Turn the battery disconnect switch to the ONposition.

Replace1. Park the machine on level ground. Lower thedozer blade to the ground. Move the transmissioncontrol to the NEUTRAL position and engage theparking brake. Shut off the engine.

2. Turn the battery disconnect switch to the OFFposition.

3. Open both the right-hand and left-hand engineaccess doors.

4. Rotate belt tensioner (1) clockwise in order torelease the tension from the belt with a 12.7 mm(0.5 inch) square drive tool.

5. Remove the belt.

6. Install the new belt. Be certain that the belt isproperly aligned in the grooves of crankshaft drivepulley (7), idler pulley (2), alternator pulley (4), andair conditioner compressor pulley (5).

7. Allow the belt tensioner to rotate counterclockwiseagainst the belt in order to provide proper tension.

8. Close the engine access doors.

9. Turn the battery disconnect switch to the ONposition.

i04045481

Braking System - TestSMCS Code: 4100-081; 4267-081

If the machine moves during the test, reduce theengine 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 repairedbefore returning the machine to operation.

Note: The machine can drive through the brakesin first gear.

Make sure that the area around the machine is clearof personnel and clear of obstacles.

Test the brakes on a dry, level surface.

Fasten the seat belt before you test the brakes.

1. Disable EAS.

Reference: See the Operation and MaintenanceManual, “Operator Controls”, and refer to section“Enhanced Auto Shift (EAS)” for more information.

2. Start the engine.

3. Raise all attachments.


4. Depress the service brake pedal.

5. Release the parking brake.

6. While the service brake pedal is depressed, movethe directional control to the SECOND SPEEDFORWARD position.

7. Gradually increase the engine speed to full loadspeed. The machine should not move.

8. Move the directional control to the NEUTRALposition.

9. Reduce the engine speed to LOW IDLE. Engagethe parking brake. Lower all attachments to theground. Apply a slight down pressure. Stop theengine.

NOTICEIf the machine moved while testing the brakes, contactyour Caterpillar dealer. Have the dealer inspect and,if necessary, repair the service brake before returningthe machine to operation.


Bulldozer Tilt Brace and Tilt Cylinders - Lubricate

i04550550

Bulldozer Tilt Brace and TiltCylinders - LubricateSMCS Code: 5104-086; 6050-086; 6074-086

Lubricate the two fittings with CAT multipurpose typegrease with molybdenum disulfide (MPGM).


One fitting is located at the left front brace assemblyor left tilt cylinder (if equipped).

The other fitting is located at the rod end of the righttilt cylinder.

Refer to Special Publication, SEBU6250, “CaterpillarMachine Fluids Recommendations” for moreinformation about MPGM.

i04316512

Cab Filter (Fresh Air) -Clean/Inspect/ReplaceSMCS Code: 7342-040; 7342-070; 7342-510

Cab Filter (Fresh Air)

Clean/Inspect/Replace


Cab Fresh Air Filter Assembly


Expanded View of Filter Assembly Components

Note: Use three points of contact when you accessthe cab filter (fresh air).

Reference: See Operation and Maintenance Manual,“Mounting and Dismounting” for more information.

This filter assembly is located outside of the left-handcab window.

1. The filter cover (1) is located at the front end ofthe filter assembly. Release three clamps (2) andremove the filter cover .

2. Remove filter element (3).

144 SEBU8593-01Maintenance SectionCab Filter (Recirculation) - Clean/Inspect/Replace

Personal injury can result from air pressure.

Personal injury can result without following prop-er procedure. When using pressurized air, wear aprotective face shield and protective clothing.

Maximum air pressure at the nozzle must be lessthan 205 kPa (30 psi) for cleaning purposes.

3. The filter element can be cleaned by usingpressurized air. Use a maximum air pressure of205 kPa (30 psi). Direct the air from the clean sideto the dirty side.

4. Inspect the element for damage. Inspect thegaskets for damage. Replace damaged filters.

5. Install filter element (3) and install filter cover (1).Fasten three clamps (2).

Note: Use three points of contact when you installthe cab filter (fresh air).

Note: Clean the filters more often in dusty conditions.

i04317289

Cab Filter (Recirculation) -Clean/Inspect/ReplaceSMCS Code: 7342-040; 7342-070; 7342-510

The recirculation filter is positioned to the left of theoperator seat base in the cab.

g02476617Illustration 181Area to left of operator seat base. Seat assembly removed toenhance visibility.

1. Unscrew fastener (1) to cover of recirculationfilter (2) and remove the cover. Remove therecirculation filter element. Access to the filter canbe improved by sliding the seat fully forward.




2. The recirculation filter element can be cleanedby using pressurized air. Use a maximum airpressure of 205 kPa (30 psi). Direct the air fromthe clean side to the dirty side.

3. Look through the filter toward a bright light. Inspectthe element for damage. Inspect the gaskets fordamage. Replace damaged filters.

4. Install the recirculation filter element. Make surethat the filter element is centered. If the filter is notcentered, the system will not function properly.

5. Install the filter cover and secure with the fastener.

Note: Clean the filters more often in dusty conditions.

i03680600

Camera - Clean/Adjust(WAVS (If Equipped))SMCS Code: 7348

In order to maintain sufficient vision, keep the WorkArea Vision System (WAVS) camera lens and thedisplay clean.

g01223034Illustration 182The WAVS display is located in the operator station.


Cooler Cores and A/C Condenser - Clean

Use a soft, damp cloth in order to clean the display.The display has a soft plastic surface that can beeasily damaged by an abrasive material. The displayis not sealed. Do not immerse the display withliquid.

g01223051Illustration 183A WAVS camera is located on the rear of the machine, mountedon top of the ROPS, or mounted on the fuel tank.

Use a damp cloth or water spray in order to cleanthe camera lens. The camera is a sealed unit. Thecamera is not affected by high pressure spray.

Note: The camera is equipped with an internal heaterto help counteract the effects of condensation, snow,or ice.

For more information on WAVS, refer to Operationand Maintenance Manual, SEBU8157, “Work AreaVision System”.

i04560091

Cooler Cores and A/CCondenser - CleanSMCS Code: 1064-070; 1353-070; 1374-070;7320-070

Cooler CoresThe following cooler cores are cooled by the hydraulicfan that is located in the radiator guard at the frontof the track-type tractor.

Aftercooler core – The aftercooler core cools theinlet manifold air to the engine.

Hydraulic oil cooler core – The hydraulic oil coolercore cools hydraulic oil.

Radiator core – The radiator core cools the enginecoolant.

g02476735Illustration 184(1) Aftercooler Core(2) Radiator Core(3) Cleanout Slot Located Behind Access Cover(4) Hydraulic Oil Cooler Core

Radiator Core

You can use compressed air, high-pressure water,or steam to remove dust and other debris from theradiator core. However, the use of compressed airis preferred.

See Special Publication, SEBD0518, “Know YourCooling System” for the complete procedure forcleaning the radiator core.

Remote Air Conditioner (A/C) CondenserCore

In this machine arrangement, the a/c condenser coreis remotely located. A remote mounted a/c condensercore is cooled by fans with electric drive.

g02511127Illustration 185Air conditioner condenser unit outside of the right-hand cab window

146 SEBU8593-01Maintenance SectionCooler Cores and A/C Condenser - Clean

Inspect

Note: Adjust the frequency of inspection according tothe effects of the operating environment.

g02476830Illustration 186(1) Right-hand Engine Access Door(3) Cleanout Slot Located Behind Access Cover

Turn off the engine.

Open both engine access doors (1).

Inspect the cooling system for the followingconditions: coolant leaks, oil leaks, damaged fins,and tubes. Inspect the following parts of the coolingsystems: air lines, connections, and clamps fordamage. Make repairs for damage, if necessary.

Note: If parts of the aftercooler system appear tobe damaged or if parts of the aftercooler systemare repaired, a leak test is highly recommended.Refer to Special Instruction, SEHS8622, “Using theFT1984 Air-to-Air Aftercooler Leak Test Group”. TheFT-1984 Aftercooler Testing Group can be used foraftercoolers that have hoses with an inside diameterof 102 mm (4.00 inch) or 114 mm (4.50 inch).

For more detailed information on testing andinspection, see Special Publication, SEBD0518,“Know Your Cooling System”.

Clean


Personal injury can result without following prop-er procedure.When using pressure air, wear a pro-tective face shield and protective clothing.


Radiator cores, aftercooler cores, hydraulic oil coolercores, and a/c condenser cores needed to be cleanedregularly. Adjust the frequency of cleaning accordingto the effects of the operating environment.

Cooler Cores

All machine arrangements have a remote mounteda/c condenser core, and a single plane of thefollowing cores: hydraulic oil cooler core, radiatorcore, and aftercooler core. Additionally, thesearrangements may have a hydraulic fan that reversesthe direction of air flow in order to purge debris.

Clean




NOTICEPressurized air: To avoid possible engine damage,shut off engine before performing maintenance toclean the cooling system. Install air nozzle into accessslot before starting air supply. Read and understandOperation and Maintenance Manual.

In applications with high levels of airborne debris,a regular schedule for cleaning the cooling coresmust be established. The frequency of cleaningand the method of cleaning must be tailored to thespecific debris accumulation on the job site. In orderto maintain clean cores, the cleaning will need to bedone at least daily. Cleaning may be needed on amore frequent basis. The clean out schedule must befollowed even when ambient temperatures are low.This schedule will prevent debris accumulation in thecores and future plugging.

Access to the cores can be made through the engineaccess doors from the rear of the cores. Accessfrom this direction results in blowing air in the samedirection as the normal air flow through the fan. Allmachine arrangements offer two options for blowingair in the opposite direction of normal fan air flow.First, the reverse fan function has a continuousreverse mode. This mode allows prolonged periodsof the reverse flow while the machine is parked. Next,slots (3) are provided in both sides of the radiatorguard for use with a 307-6728 Air Nozzle whichconcentrates air flow backward through the cores.


Cooler Cores and A/C Condenser - Clean

Blow out the cores with compressed air. Move theair nozzle in a systematic pattern so that the air flowcovers the whole core that includes the areas in thecorners. Do not use steam or high-pressure water forcleaning frequently. If steam or high-pressure wateris required to dislodge any debris that is held deep inthe cores, make sure that the cleaning is thorough.This cleaning may require opening radiator doorsand removing debris guards for access. Incompletecleaning with water may cause remaining debris toharden in place. Use lights and wire probes in orderto ensure that the cleaning is thorough and complete.If the debris has hardened in the center of the cores,these cores may need removed from the machine forthorough cleaning. If steam or water pressure is usedto clean the cores, make sure that the pressure iscontrolled in order to prevent the fins from bending.

If you use a degreaser or special cleaning agents,wash the core with detergent and hot water.Thoroughly rinse the core with clean water. Dry thecores completely before operating the machine inthe work mode.

Dry

If steam or water is used to clean the cores, makesure that the cores are dried completely before thetrack-type tractor is put back to work.

Use compressed air to blow dry the wet cores, theengine, engine access doors, and the hood.

Close both engine access doors.

If the machine is in a clean environment, start theengine and allow the fan to run continuously in thereverse mode until the cooling system has driedcompletely. Allow the machine to sit overnight beforeoperating the machine in the work mode.

Typical Cleaning Procedure That UsesCompressed Air

All machine arrangements may have special cleaningfeatures.

• continuous reverse fan function

• 307-6728 Air Nozzle in access slots in the radiatorguard

These tools can be used to develop a cleaningprocedure that best suits your application. Onepossible sequence for cleaning is outlined below.

g02726215Illustration 187(3) Cleanout Slot Behind Access Cover

1. At the proper cleaning area, park the machine inNEUTRAL and engage the parking brake.

2. Depress the fan control switch and hold for3 seconds in order to enter the continuousreverse mode. Run the fan in the reverse modecontinuously for 2 minutes.

3. Turn off the engine. Make sure that the fan hasstopped rotation.

4. Open both engine access doors. Use a regularair nozzle to clean the cores from the rear side.Blow off the hood, engine access doors, and theentire engine compartment. On machines that areequipped with the woodchip arrangement, openthe grill doors and blow off the shelf of the radiatorguard.

5. Open the cover to access slot (3) on both sidesof the radiator guard. Insert the 307-6728 AirNozzle into the access slot on the right side of themachine in order to clean the cores on the leftside of the machine.

Note: Cleaning the cores from the opposite side ofthe machine allows better cleaning in the corners.

6. Turn on the air supply.

Note: Do not activate the air supply until you haveinserted the air nozzle into the access slot. Use thework tool safely.

7. Move the air nozzle in a pattern in order to cleanthe cores from the front side of the cores. Blow outthe cores on the left side of the cooling system.

148 SEBU8593-01Maintenance SectionCooling System Coolant (ELC) - Change

8. Turn off the air supply when the nozzle cleaning ofthe left side cores is completed.

9. Remove the air nozzle from the access slot. Closethe access cover.

10.Repeat Steps 5 through 9 from the left side of themachine in order to clean the cores on the rightside of the machine.

11.Use a regular air nozzle in order to blow off thecores from the rear and clean the entire enginecompartment.

12.Close both of the engine access doors.

13.Restart the engine. Operate the fan in the forwarddirection continuously for 2 minutes.

14.Reverse the air flow. Operate the fan in thereverse mode continuously for 2 minutes.

15.Return to operating the machine in work mode.

Note: Adjust the frequency of cleaning according tothe effects of the operating environment. Modify thetypical cleaning procedure above for optimal results,as needed.

i04556758

Cooling System Coolant (ELC)- ChangeSMCS Code: 1395-044

For information about adding an extender to yourcooling system, see the Topic “Cooling SystemCoolant Extender (ELC) - Add” in this manual orconsult your Caterpillar dealer.

NOTICEMake sure you read and understand the informationin the topics Safety and Cooling System Specifica-tions for all information pertaining to water, antifreezeand supplemental coolant additive requirements be-fore you proceed with maintenance of the cooling sys-tem.

To Drain the Cooling SystemThe filler cap is located beneath the access cover ontop of the hood, forward of the engine air precleaner.


1. Put the machine on a hard level surface, set theparking brake, and turn off the engine.

Personal injury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant orsteam. Any contact can cause severe burns.

Remove filler cap slowly to relieve pressure onlywhen engine is stopped and radiator cap is coolenough to touch with your bare hand.

Cooling SystemConditioner contains alkali. Avoidcontact with skin and eyes.

2. Slowly loosen filler cap (1) in order to relievesystem pressure. Remove the filler cap.


3. Remove access cover (2) for the coolant drain.The cover is located on the right side near thefront of the bottom engine guard.


Cooling System Coolant (ELC) - Change

g02477560Illustration 190Coolant drain valve viewed through access hole in bottom engineguard

4. Remove plug (3) from the drain valve. Install a12.7 mm (.5 inch) drain pipe into the drain valve.The pipe must have 1/2 - 14 NPTF threads. Clampa hose to the pipe in order to direct the coolantinto a suitable container.

5. Open drain valve (4). Allow the coolant to draininto a suitable container.

6. Flush the system with water. Flush the systemuntil the draining water is clear.

Note: If the cooling system is already using ELC,cleaning agents are not required at the specifiedcoolant change interval. Cleaning agents are onlyrequired if the system has been contaminated by theaddition of some other type of coolant or by coolingsystem damage. Clean water is the only cleaningagent that is required when ELC is drained from thecooling system.

Note: If you change to ELC from another type ofcoolant, use a Caterpillar cleaning agent to flushthe cooling system. After you drain the coolingsystem, thoroughly flush the cooling system withclean water. All of the cleaning agent must beremoved from the cooling system. Refer to theTopic “Cat Extended Life Coolant (ELC)” in Operationand Maintenance Manual, SEBU6250.

7. Close drain valve (4), then remove the drain pipeif previously installed. Install plug (3).

8. Replace access cover (2).

9. Add the ELC solution. See the following topics inthis publication:

• Cooling System Specifications

• Capacities (Refill)

Note: Caterpillar antifreeze contains additives. Ifyou are using Caterpillar antifreeze, do not add thesupplemental coolant additive at this time. Also,do not change the supplemental coolant additiveelement at this time.

10.After the cooling system has been filled, performthe following procedures during initial start-up:

a. Start the engine without the filler cap.

b. Run the engine at low idle for 10 minutes.

c. Then, increase the engine speed to a high idleuntil the thermostat is open and the coolantlevel is stabilized.

d. Maintain the coolant at the proper level as thethermostat opens, and air is purged from thesystem. Refer to Operation and MaintenanceManual, “Cooling System Coolant Level -Check”.

11.Stop the engine.

12.Clean the radiator core with compressed air. Youmay need to use water in order to remove debris.

Reference: See Operation and MaintenanceManual, “Cooler Cores and A/C Condenser- Clean” for information on a typical cleaningprocedure.

13.Allow the radiator core to dry completely beforeoperating the machine in the work mode.

For additional information about the cooling systemcoolant, see Special Publication, SEBD0518,“Know Your Cooling System” Also, see Operationand Maintenance Manual, SEBU6250, “CaterpillarMachine Fluids Recommendations”, “Cat ExtendedLife Coolant (ELC)” or consult your Caterpillar dealer.

150 SEBU8593-01Maintenance SectionCooling System Coolant Extender (ELC) - Add

i04321966

Cooling System CoolantExtender (ELC) - AddSMCS Code: 1352-538; 1395-538

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.

Refer to Special Publication, NENG2500, “Dealer Ser-vice Tool Catalog” for tools and supplies suitable tocollect and contain fluids on Cat products.

Dispose of all fluids according to local regulations andmandates.

When a Caterpillar Extended Life Coolant (ELC)is used, an extender must be added to the coolingsystem. See the Operation and MaintenanceManual, “Maintenance Interval Schedule” for theproper service interval. The amount of extender isdetermined by the cooling system capacity.

For additional information about adding an extender,see Special Publication, SEBU6250, “CaterpillarMachine Fluids Recommendations” or consult yourCaterpillar dealer.

Extended Life Coolant (ELC)ExtenderUse a 8T-5296 Coolant Conditioner Test Kit tocheck the concentration of the coolant.

Personal injury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant orsteam. Any contact can cause severe burns.

Remove filler cap slowly to relieve pressure onlywhen engine is stopped and radiator cap is coolenough to touch with your bare hand.

Cooling SystemConditioner contains alkali. Avoidcontact with skin and eyes.


1. The filler cap is located beneath the access coveron top of the hood, forward of the engine airprecleaner. Loosen the radiator cap slowly in orderto relieve pressure. Remove the radiator cap.

2. Draining some coolant from the radiator may benecessary so that Extender can be added to thecooling system.

Note: Always discard drained fluids according tolocal regulations.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the machine. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.

Refer to Special Publication, NENG2500, “CaterpillarTools and Shop Products Guide”, for tools and sup-plies suitable to collect and contain fluids in Caterpillarmachines.


3. Add proper mixture of Extender to the coolingsystem.

4. Start the engine. Run the engine without the fillercap until the thermostat opens and the coolantlevel stabilizes. Check for leaks.

5. Maintain the coolant at the proper level as thethermostat opens, and air is purged from thesystem. Refer to Operation and MaintenanceManual, “Cooling System Coolant Level - Check”.

6. Inspect the radiator cap for any signs of damage.Replace if necessary. Install the radiator cap.


Cooling System Coolant Level - Check

i04556765

Cooling System Coolant Level- CheckSMCS Code: 1353-535-FLV; 1395-535-FLV

At operating temperature, the engine coolant ishot and under pressure.

Steam can cause personal injury.

Check the coolant level only after the engine hasbeen stopped and the fill cap is cool enough totouch with your bare hand.

Remove the fill cap slowly to relieve pressure.

Cooling system conditioner contains alkali. Avoidcontact with the skin and eyes to prevent personalinjury.

The machine cooling system has a surge tank. Thereis no top tank on the radiator. The surge tank has afiller cap and a sight glass. The removal of the fillercap is not necessary in order to check the coolantlevel. The sight glass is inside the engine accessdoor on the right-hand side of the machine. The fillercap is beneath the access cover on top of the hood,forward of the engine air precleaner.


1. Observe sight glass (1) in order to verify the levelof the coolant. If the coolant completely covers thesight glass, the coolant level is okay. If no coolantis present in the sight glass, the coolant is low. Ifthe coolant level line is visible in the sight glass,the coolant is low. Add coolant in order to fill thesystem.

2. If necessary to add coolant, remove filler cap (2)slowly in order to relieve the pressure.

Note: The factory fill is Extended Life Coolant(ELC). Refer to Operation and MaintenanceManual, SEBU6250, “Caterpillar Machine FluidsRecommendations” for additional information.Maintaining the system as ELC is preferred. Seethe sections “Coolant Recommendations” and “ELCCooling System Maintenance”.

3. Inspect the filler cap and the filler cap seal fordebris, for foreign material, or for damage. Cleanthe filler cap with a clean cloth. Replace theradiator cap if the filler cap is damaged.

4. Install the filler cap.

5. Inspect the radiator core for debris. Clean theradiator core, if necessary.

Reference: See Operation and MaintenanceManual, “Cooler Cores and A/C Condenser- Clean” for information on a typical cleaningprocedure.

6. Allow the radiator core to dry completely beforeoperating the machine in the work mode.

i04320903

Cooling System CoolantSample (Level 2) - ObtainSMCS Code: 1350-008; 1395-008; 1395-554; 7542

Level 2 Analysis

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.




152 SEBU8593-01Maintenance SectionCooling System Water Temperature Regulator - Replace

Testing the coolant can be done at your Caterpillardealer. Caterpillar S·O·S Coolant Analysis is thebest way to monitor the condition of your coolantand your cooling system. S·O·S Coolant Analysis isa program that is based on periodic samples. SeeOperation and Maintenance Manual, SEBU6250,“Cooling System Specifications”, “General CoolantInformation” for more information.

Perform a Coolant Analysis (Level 2) at initial 500hours for systems that contain extended life coolant(ELC). Perform the analysis yearly after the initial500 hours.


(1) Coolant Level Sight Glass(2) Coolant Sampling Valve

1. Park the machine on a hard, level surface. Set theengine at low idle speed. Set the parking brake

2. Open the right-hand side engine access door. Usethe location of the coolant tank and Coolant LevelSight Glass (1) for reference. Locate CoolantSampling Valve (2) and remove the protective cap.

3. Obtain a coolant sample while the engine isrunning and at the correct operating temperature.For additional information about coolant analysis,see Operation and Maintenance Manual,SEBU6250, “Cooling System Specifications”,“General Coolant Information” or consult yourCaterpillar dealer.

4. Replace the protective cap. Close the right-handside engine access door.

Submit the sample for Level 2 analysis.

i01958847

Cooling System WaterTemperature Regulator -ReplaceSMCS Code: 1355-510

NOTICEFailure to replace the engine's thermostat on a regu-larly scheduled basis could cause severe engine dam-age.

NOTICEReplace the thermostat on a regular basis in order toreduce the chance of unscheduled downtime and ofproblems with the cooling system.

A new thermostat should be installed after the coolingsystem has been cleaned. Install the thermostat whilethe cooling system is completely drained or while thecooling system coolant is drained to a level that isbelow the thermostat housing.

NOTICESince Caterpillar engines incorporate a shunt designcooling system, it is mandatory to always operate theengine with a thermostat.

Depending on load, failure to operate with a thermo-stat could result in either an overheating or an over-cooling condition.

Reference: Refer to Disassembly and Assembly,“Water Temperature Regulator - Remove” andDisassembly and Assembly, “Water TemperatureRegulator - Install” for more information. Fill theengine cooling system. Refer to Operation andMaintenance Manual, “Caterpillar Machine FluidsRecommendations” and Operation and MaintenanceManual, “Capacities (Refill)”.

i04555540

Crankshaft Vibration Damper- InspectSMCS Code: 1205-040; 1205

Debris AccumulationThe crankshaft vibration damper is most easily seenwhen viewed from the right-hand side of the machine.


Crankshaft Vibration Damper - Inspect

g02726011Illustration 194(1) Right-hand engine access door


Front of right-hand engine compartment(2) Crankshaft vibration damper(3) Engine bottom guard(4) Lower guard assembly

Open right-hand engine access door (1) and swingout lower guard assembly (4) in order to view thelower area at the front of the engine.

Mud, soil, and other debris may accumulate aboveengine bottom guard (3) in certain operatingconditions. Inspect the area around crankshaftvibration damper (2) for accumulation of suchmaterial. This material must be removed, whennecessary, so that there is no interference with thefree rotation of the crankshaft vibration damper.

Note: If debris buildup is severe enough, indicationof contact with the crankshaft vibration damper maybe seen. The paint may be worn from the crankshaftvibration damper, or the crankshaft vibration dampermay be shiny in appearance. Such evidence is acertain indication that removal of debris in necessary.

The engine bottom guard may be lowered to aidin the removal of any accumulated material. Referto Disassembly and Assembly, UENR0029, “D9TTrack-Type Tractor Engine Supplement”.

Mechanical ConditionDamage to the vibration damper or failure of thevibration damper will increase torsional vibrations.These vibrations will result in damage to thecrankshaft and in damage to the other enginecomponents. A deteriorating vibration damper willcause excessive gear train noise at variable pointsin the speed range.

See the Service Manual, “Engine Disassembly andAssembly” for the procedure to install a new damper.

Caterpillar recommends replacing the damper for anyof the following reasons:

• The engine has had a failure because of a brokencrankshaft.

• There are signs of leakage from the crankcasevibration damper case.

• There are signs of damage to the crankcasevibration damper case.

The damper can be used again if none of the aboveconditions are found. The damper can be used if thedamper is not damaged.

In the damper, a wobble can occur on the outer ring.Some of the wobble of the outer ring is normal. If awobble is present, replacement of the damper is notnecessary. You can confirm an acceptable wobble byseeing the Service Manual, “Engine Disassembly andAssembly” for the procedure to check the damper.

154 SEBU8593-01Maintenance SectionCutting Edges and End Bits - Inspect/Replace


This engine uses a viscous vibration damper unlikethe rubber vibration damper with alignment marks.The viscous vibration damper limits torsional vibrationeffectively.

NOTICEInspect the viscous vibration damper for signs of leak-ing and for signs of damage to the case. Either ofthese conditions can cause the weight to contact thecase. This contact can affect damper operation.

Note: Refer to the Service Manual, “EngineDisassembly and Assembly” for the necessaryreplacement procedure.

i04322329

Cutting Edges and End Bits -Inspect/ReplaceSMCS Code: 6801-040; 6801-510; 6804-040;6804-510


1. Raise the bulldozer blade and block up thebulldozer blade. When you remove the cuttingedges and the end bits, maintain the bulldozerblade at a minimum height.

2. Remove the bolts. Then remove the cutting edgeand the end bits.

3. Thoroughly clean all contact surfaces.

4. Inspect the opposite side of the cutting edge.If the opposite side of the cutting edge is notworn, turn the opposite side of the cutting edgedownward and install the cutting edge.

5. If both sides of the cutting edge are worn, install anew cutting edge section.

Note: When the cutting edge is within 10 mm(0.4 inch) of the bottom of the support, change thecutting edge. Do not allow wear to occur on thesupport.

6. If the bottom edge or the outside edge of the endbit is worn, install a new end bit.

Note:When the end bit is within 10 mm (0.4 inch) ofthe bottom of the support, change the end bit. Whenthe end bit is within 10 mm (0.4 inch) of the outsideedge of the support, change the end bit. Do notallow any wear to occur on the support.

7. Install all bolts and tighten the bolts to atorque of 1150 ± 150 N·m (850 ± 110 lb ft).Refer to Specifications, SENR3130, “TorqueSpecifications”, “Ground Engaging Tool (G.E.T.)Fasteners”.

8. Raise the bulldozer blade and remove theblocking. Lower the bulldozer blade to the ground.

9. After you operate the machine for a few hours,check all bolts for proper torque.

i02061807

Electronic Unit Injector -Inspect/AdjustSMCS Code: 1290-025; 1290-040

The Electronic Control module produces highvoltage. To prevent personal injury make sure theElectronic Control Module is not powered and theunit injector solenoids are disconnected.

NOTICEThe camshafts must be correctly timed with the crank-shaft before an adjustment of the unit injector lashis made. The timing pins must be removed from thecamshafts before the crankshaft is turned or damageto the cylinder block will be the result.


Engine Air Filter Primary Element - Clean/Replace

The operation of Caterpillar engines with improperadjustments of the electronic unit injector can reduceengine efficiency. This reduced efficiency could resultin excessive fuel usage and/or shortened enginecomponent life.

Adjust the electronic unit injector at the same intervalas the valve lash adjustment.

Refer to your machine's Service Manual or yourCaterpillar dealer for the complete adjustmentprocedure.

i04555685

Engine Air Filter PrimaryElement - Clean/ReplaceSMCS Code: 1054-070-PY; 1054-510-PY

NOTICEService the primary filter element only when the alertindicator for the intake air filter is flashing. Do not openthe filter compartment unless it is time for service.Opening the filter compartment can cause dirt to getinto the clean side of the filter housing.

NOTICEExtremely short air filter life can result if the preclean-er system malfunctions. If air filter life is drastically re-duced from typical for the operating conditions, con-sult your Caterpillar Dealer. The exhaust system dustejector for the strata tube precleaner must pull a min-imum vacuum of 508 mm (20 inch) of water.

NOTICEService the engine air filters with the engine stopped.Engine damage could result.

NOTICEAlways leave the secondary filter element in placewhile you clean the primary element, or while youclean the air cleaner housing.

NOTICEDo not use the filter for longer than one year.

g02723880Illustration 198Engine air cleaner

1. Open the left-hand engine access door, ifequipped. The engine air cleaner is located at therear of the engine compartment above the muffler.


(1) Retaining clamps(2) Air cleaner cover(3) Alignment notch(4) Primary air filter element

2. Release three retaining clamps (1) that secureair cleaner cover (2) to the air cleaner housing.Remove air cleaner cover.

Note: The air cleaner cover can be installed in onlyone position. Notice the position of alignment notch(3) during cover removal in order to assist with coverinstallation later.

3. Remove primary air filter element (4) from the aircleaner housing by pulling outward while gentlymoving the element from side to side.

156 SEBU8593-01Maintenance SectionEngine Air Filter Primary Element - Replace

g02723980Illustration 200(4) Primary air filter element(5) Secondary air filter element(6) Air cleaner housing

4. Mark secondary filter element (5) in order to showthat the primary filter element has been serviced.The secondary filter element should be replacedwhen the primary filter element is serviced for thethird time. Refer to Operation and MaintenanceManual, “Engine Air Filter Secondary Element -Replace” for more information.

5. Clean the inside of air cleaner housing (6). Keepthe secondary filter element in place while youclean the housing.

6. If the primary filter element has not been cleanedsix times, inspect the primary filter element. Ifthe primary filter element has been cleaned sixtimes, replace the primary filter element. Proceedto Step 9.

7. Inspect the primary filter element. Inspect thefilter element for holes and for tears by lookingthrough the filter element. Look toward a brightlight. Inspect the element for damaged gaskets orfor dented metal parts. Replace damaged filters.Always crush damaged filter elements. Properlydiscard the filter elements. If you replace theprimary filter element, proceed to Step 9.

8. If the primary filter element is not damaged andthe element has not been previously cleaned sixtimes, clean the element. The filter element canbe cleaned by using pressure air. Use a maximumair pressure of 205 kPa (30 psi). Direct the airfrom the clean side to the dirty side. In order toshow that the filter element has been cleaned,mark the element. The primary filter element canbe cleaned up to six times.

NOTICEDo not clean the filter elements by bumping or tappingthem. Do not use filter elements with damaged pleats,gaskets, or seals. Do not wash the filter elements.

9. Push the filter element firmly in order to properlyseat the element. Write the date on the element ifthe primary element is replaced.

10. Install the air cleaner cover. The air cleaner covercan be installed in only one position. The aircleaner cover must be rotated so that alignmentnotch (3) in the cover is aligned with the alignmentpin of the air cleaner housing. Secure the aircleaner cover with the three retaining clamps.

11.Close the engine access door, if equipped.

i01854524

Engine Air Filter PrimaryElement - ReplaceSMCS Code: 1054-510-PY

NOTICEThe filter should be kept in service for no longer thanone year.

Refer to Operation and Maintenance Manual, “EngineAir Filter Primary Element - Clean/Replace” for thereplacement procedure.

Write the date on the element, when the element isreplaced.

i04556175

Engine Air Filter SecondaryElement - ReplaceSMCS Code: 1054-510-SE

NOTICEAlways replace the secondary filter element. Neverattempt to reuse it by cleaning.

The secondary filter element should be replaced at thetime the primary element is serviced for the third time.

The secondary filter element should also be replacedif the yellow piston in the filter element indicator en-ters the red zone after installation of a clean primaryelement, or if the exhaust smoke is still black.

NOTICEThe filter should be kept in service for no longer thanone year.


Engine Air Precleaner - Clean

NOTICEAlways leave the secondary filter element in placewhile you clean the air cleaner housing.

1. Open the left-hand engine access door, ifequipped.

2. Remove both the air cleaner housing cover andthe primary air filter element. Refer to Operationand Maintenance Manual, “Engine Air FilterPrimary Element - Clean/Replace” for moreinformation.

g02724101Illustration 201Engine air cleaner with air cleaner housing cover and primaryelement removed

(1) Air cleaner housing(2) Secondary air filter element

3. Clean the inside of air cleaner housing (1).

Note: Always leave the secondary air filter elementin place when cleaning the inside of the air cleanerhousing.

4. Remove secondary air filter element (2). Pull outwith a side to side movement in order to removethe element.

5. Install a new secondary filter element. Pushthe element firmly in order to properly seat theelement. Write the date on the element, if theelement is replaced.

6. Install the primary filter element and the aircleaner housing cover. Refer to Operation andMaintenance Manual, “Engine Air Filter PrimaryElement - Clean/Replace” for more information.

7. Close the left-hand engine access door, ifequipped.

i04557064

Engine Air Precleaner - CleanSMCS Code: 1055-070


1. Inspect the screen in the engine air precleanerthat sits above engine hood for dirt accumulation.

2. Loosen retainer (2) and remove screen (1).

3. Clean the screen with compressed air or water.

4. Replace the screen.

i04555443

Engine Mounts - InspectSMCS Code: 1152-040; 1152

Engine MountsCaterpillar recommends checking the engine mountsfor deterioration. This recommendation will preventexcessive engine vibration that is caused fromimproper mounting.

i04324335

Engine Oil Level - CheckSMCS Code: 1302-535-FLV; 1326-535-FLV

Hot oil and components can cause personal in-jury.

Do not allow hot oil or components to contactskin.

158 SEBU8593-01Maintenance SectionEngine Oil Sample - Obtain

NOTICEDo not under fill or overfill engine crankcase with oil.Either condition can cause engine damage.

1. Park the machine on level ground.

2. Open the engine access door on the left-handside of the machine.


3. Remove engine oil level gauge (1). Examine theoil level gauge in order to determine the engine oillevel. The gauge can be read on both sides. Oneside is marked “ENGINE STOPPED”. The otherside is marked “ENGINE LOW IDLE”.


4. Maintain the oil level within operating range (X),between the “ADD” mark and the “FULL” mark onthe oil level gauge.

a. When the engine is stopped and the oil is cold(ambient temperature), maintain the oil levelon the “ENGINE STOPPED” side of the oillevel gauge. This method should be used asreference only, before the engine is started.

b. When the engine is running and the oil is warm(operating temperature), maintain the oil levelon the “ENGINE LOW IDLE” side of the oil levelgauge. This procedure is the only accurate wayto check the oil level.

Note: When you operate the machine on severeslopes, the oil level in the engine crankcase must beat the “FULL” mark. Check the level on the “ENGINELOW IDLE” side of oil level gauge(1).

5. If necessary, remove the oil filler cap (2) and addoil. Clean the filler cap and install the filler cap.

6. Close the engine access door.

i04327029

Engine Oil Sample - ObtainSMCS Code: 1348-554-SM; 1348; 7542






Obtain the sample of the engine oil as close aspossible to the recommended sampling interval. Inorder to receive the full effect of S·O·S oil analysis,establish a consistent trend of data. In orderto establish a pertinent history of data, performconsistent oil samplings that are evenly spaced.

1. Before you obtain an oil sample, operate themachine until the oil is warm and circulated.

2. Open the engine access door on the left-handside of the machine.


Engine Oil and Filter - Change

g02482356Illustration 205Engine oil sampling valve

3. Remove the protective cap.

4. Obtain a sample of the engine oil from theengine oil sampling valve. Refer to SpecialPublication, SEBU6250, “Caterpillar MachineFluids Recommendations”, “S·O·S Services OilAnalysis” for information that pertains to obtaininga sample of the engine oil. Refer to SpecialPublication, PEHP6001, “How To Take A Good OilSample” for more information about obtaining asample of the engine oil.

Note: In order to obtain an oil sample from the enginecompartment, increasing the engine speed may benecessary. Normally, the oil sample is taken at lowidle. If the flow rate is too low, increase engine speedto high idle in order to obtain the oil sample.

5. Replace the protective cap.


For additional information about oil sampling consultyour Cat dealer.

i04558729

Engine Oil and Filter - ChangeSMCS Code: 1308; 1318-510

Selection of the Oil Change Interval

NOTICEThis machine is equipped with an engine that meetsEPA Tier III, Euro Stage II, or MOC Step 2 emissionregulations. A 500 hour engine oil change intervalis available, if operating conditions and recommend-ed multigrade oil types are met. When these require-ments are not met, shorten the oil change interval to250 hours, or use an S·O·S oil sampling and analysisprogram to determine an acceptable oil change inter-val.

If you select an interval for oil and filter change that istoo long, you may damage the engine.

CAT oil filters are recommended.

Recommended multigrade oil types are listed in Table27. Do not use single grade oils.

Abnormally harsh operating cycles or harshenvironments can shorten the service life ofthe engine oil. Arctic temperatures, corrosiveenvironments, or extremely dusty conditionsmay require a reduction in engine oil changeintervals from the recommendations in Table 27.Also refer to Manual, SEBU5898, “Cold WeatherRecommendations”. Poor maintenance of air filtersor of fuel filters requires reduced oil change intervals.See your Caterpillar dealer for more information if thisproduct will experience abnormally harsh operatingcycles or harsh environments.

160 SEBU8593-01Maintenance SectionEngine Oil and Filter - Change

Table 27

D9T Series (S/N: TWG1-Up)Engine Oil Change Interval(1)

Operating Conditions

Severe

FuelSulfurabove0.3%(2)

MultigradeOil Type Standard

(1)Extended

(1)

Altitudeabove1830 m(6000ft)

Cat DEOPreferred 250 hr 500 hr 250 hr 250 hr(3)

ECF-2Preferred 250 hr 500 hr 250 hr 250 hr

ECF-1-a 250 hr 250 hr 150hr(3) 250 hr(3)

(1) The standard oil change interval for engines is 250 hours.The extended oil change interval in this machine is 500 hoursif the following conditions are met. Acceptable operatingconditions, recommended oil types, and an S·O·S oil samplingand analysis program are used. This extended interval is notpermitted for other machines. Refer to the applicable Operationand Maintenance Manuals for the other machines.

(2) For sulfur content above 0.1%, refer to this topic in the Manual,SEBU6250, “Caterpillar Machine Fluid Recommendations”.

(3) Use Program B below to determine an appropriate interval.

Adjustment of the Oil Change Interval

Note: Your Cat dealer has additional information onthis program.

Program B

Optimizing Oil Change Intervals

Begin with a standard oil change interval. The oilchange intervals are adjusted by increments. Eachinterval is adjusted an additional 50 hours. Periodic oilsampling and analysis are done during each interval.The analysis includes oil viscosity and infrared (IR)analysis of the oil. Repeat Program B if you changethe application of the machine.

If an oil sample does not pass the analysis, shortenthe oil change interval.

References

Reference: Form, PEDP7035, “Optimizing OilChange Intervals”

Reference: Form, PEDP7036, “S·O·S Fluid Analysis”

Reference: Form, PEHP7076, “Understanding theS·O·S Oil Analysis Tests”

Procedure for Changing the EngineOil and Filter






g02483077Illustration 206Crankcase drain access cover on left-hand side of bottom engineguard

1. Remove two bolts in order to remove thecrankcase drain access cover. The drain accesscover is located on the left-hand side of the bottomengine guard.


Engine Oil and Filter - Change

g02485637Illustration 207Engine oil drain adapter and drain valve behind crankcase drainaccess cover

2. Remove drain plug (1) from the drain adapter.

3. Install a 25.4 mm (1.00 inch) pipe into the drainadapter. The pipe requires a 1-11 1/2 NPTF pipethread. A drain hose may be attached to the pipeto aid in draining.

4. Open the drain valve (2). Allow the oil to drain intoa suitable container.

5. When the oil has completed draining from thecrankcase, close the drain valve (2). Remove thepipe. Install the drain plug (1). Install the accesscover.


6. Open the engine access door on the left-hand sideof the machine. Remove engine oil filter element(3) and discard the engine oil filter elementproperly. Make certain that all of the old filter sealis removed from the filter base.

7. Apply a thin coat of oil to the seal on the new filter.Install the new engine oil filter element by hand.When the gasket contacts the filter base, tightenthe filter element by an additional 3/4 turn (270degrees). Rotation index marks are on the newfilter element. These rotation index marks arespaced at 90 degree intervals. Use these rotationindex marks as a guide for proper tightening.

8. Remove oil filler cap (4). Fill the crankcase withnew oil. See the topic Operation and MaintenanceManual, “Capacities (Refill)” in this manual. Cleanoil filler cap (4) and install the oil filler cap.

9. To ensure that the correct amount of oil wasadded, always measure the oil level with theengine oil level gauge (5).

10.Remove engine oil level gauge (5). Examine theoil level gauge in order to determine the engine oillevel. The gauge can be read on both sides. Oneside is marked “ENGINE STOPPED”. The otherside is marked “ENGINE LOW IDLE”.


11.Maintain the oil level within operating range (X),between the “ADD” mark and the “FULL” mark onthe oil level gauge.

a. When the engine is stopped and the oil is cold(ambient temperature), maintain the oil levelon the “ENGINE STOPPED” side of the oillevel gauge. This method should be used asreference only, before the engine is started.

b. When the engine is running and the oil is warm(operating temperature), maintain the oil levelon the “ENGINE LOW IDLE” side of the oil levelgauge. This procedure is the only accurate wayto check the oil level.

Note: When you operate the machine on severeslopes, the oil level in the engine crankcase must beat the “FULL” mark. Check the level on the “ENGINELOW IDLE” side of oil level gauge(5).

12. If necessary, remove the oil filler cap (4) and addoil. Clean the filler cap and install the filler cap.

For additional information about oil types, see SpecialPublication, SEBU6250, “Caterpillar Machine FluidsRecommendations” or consult your Caterpillar dealer.

162 SEBU8593-01Maintenance SectionEngine Valve Lash - Check/Adjust

High Speed Oil Change (If Equipped)

Open the engine access door on the left-hand side ofthe machine. Swing out the lower guard assembly toreveal the high speed oil change connection fittings.

g02725488Illustration 210(6) Engine high speed oil change connection fitting (if equipped)(7) Power train high speed oil change connection fitting (if

equipped, reference only)

Engine high speed oil change connection fitting (ifequipped) (6) can be used with additional equipmentto change the engine oil. The filter will still needchanged as described previously.

i02092049

Engine Valve Lash -Check/AdjustSMCS Code: 1102-025; 1102

To prevent possible injury, do not use the startermotor to turn the flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring valve clearance.

Electrical shock hazard. The electronic unit injec-tor system uses 90-120 volts.

NOTICEOperation of Caterpillar engines with improper valveadjustments will reduce engine efficiency. This re-duced efficiency could result in excessive fuel usageand/or shortened engine component life.

NOTICEMeasure the valve clearance with the engine stopped.To obtain an accurate measurement, allow at least 20minutes for the valves to cool to engine cylinder headand engine block temperature.

Check the valve bridge before setting the valve lash.Ensure that the valve bridge is seated equally onboth valve stems.

Refer to your machine's Service Manual or yourCaterpillar dealer for the complete valve adjustmentprocedure.

i02092057

Engine Valve Rotators - InspectSMCS Code: 1109-040

When inspecting the valve rotators, protectiveglasses or face shield and protective clothingmust be worn, to prevent being burned by hot oilor spray.

Electrical shock hazard. The electronic unit injec-tor system uses 90-120 volts.


1. Start the engine. Run the engine at low idle.


Equalizer Bar - Inspect


2. Watch the top surface of each valve rotator.Whenever an inlet valve closes or an exhaustvalve closes, each valve rotator should turn.

3. If a valve rotator fails to rotate, consult yourCaterpillar dealer for service.

Note: Caterpillar recommends replacing valverotators that are operating improperly. An improperlyoperating valve rotator will shorten valve life becauseof accelerated wear on the valves.

Note: If a damaged valve rotator is not replaced,some valve face guttering could result. Metal particlesfrom the valve could fall into the cylinder. This couldcause damage to the piston head and to the cylinderhead.

i04555533

Equalizer Bar - InspectSMCS Code: 7206-040; 7207-040

Equalizer Bar End Pins

Personal injury or death can occur from not fol-lowing the proper procedure or the recommendedtooling.

To prevent the possibility of injury or death, followthe established procedure using the recommend-ed tooling.

NOTICEThe machine must be parked on a level surface toperform this procedure.

Note: All the weight of the machine must be removedfrom the equalizer bar. Equalizer bar must have freemovement in order to be measured.

To check the equalizer bar end pin for movement andunusual wear, perform the following steps.


1. Clean the areas that are around the end pin with ahigh-pressure wash. Inspect the condition of theseal.

2. Check the area for a neutral seal position and forsigns of grease leakage.


164 SEBU8593-01Maintenance SectionEqualizer Bar - Inspect

3. Position a dial indicator on the bracket for the pinon the roller frame. Set the dial indicator probeon top of the equalizer bar. Set the dial indicatorto zero.


4. Put a 55 ton hydraulic jack in position under theend of the equalizer bar.

5. Jack up the equalizer bar and take a reading onthe dial indicator in order to determine the amountof wear.

Note: Schedule the end pin joint for repair if thereading on the dial indicator exceeds 1.50 mm(.059 inch).

6. Repeat the inspection and the measurementprocedure for the other end of the equalizer barand end pin.

Consult your Caterpillar dealer for an inspection andfor repair instructions.

Equalizer Bar Center Pin







Note: All the weight of the machine must be removedfrom the equalizer bar. Equalizer bar must have freemovement in order to be measured.

To check the equalizer bar center pin for loosenessand for unusual wear, perform the following steps.


1. Clean the areas that are around the center pinand equalizer bar.


2. Put a 55 ton hydraulic jack in position under themain frame, as shown.


Equalizer Bar End Pins - Lubricate


3. Position a dial indicator on the equalizer barand place the probe of the dial indicator underthe center of the frame for the pin. Set the dialindicator to zero.

4. Jack up the front of the machine until the weightof the roller frames are supported by the equalizerbar.

5. Take a reading of the dial indicator in order todetermine the amount of wear on the pin andbearing.

Note: Schedule the center pin joint for repair ifmovement exceeds 2.54 mm (.100 inch).

Consult your Caterpillar dealer for an inspection andfor repair instructions.

Equalizer Bar Pads


The equalizer bar pads are under the front guard,which is underneath the machine. Inspect theequalizer bar pads for cracked rubber and for missingportions of rubber. Consult your Caterpillar dealer forreplacement parts and for replacement instructions.

i04555410

Equalizer Bar End Pins -LubricateSMCS Code: 7206-086-PN; 7207-086-PN

NOTICECare should be used when adding grease to equalizerbar end pin joints. Excessive grease pressure couldcause the equalizer bar end pin seals to bulge outwardand result in a premature seal failure.

g02723711Illustration 220(1) Equalizer bar end pin lubrication fittings(2) Left-hand equalizer bar end pin

Equalizer bar end pins (2) on both the left-hand andright-hand side of the machine are lubricated froma remote location. Equalizer bar end pin lubricationfittings (1) are along the left-hand side of the engine.

g02723725Illustration 221Equalizer bar end pin lubrication fittings

(3) Right-hand equalizer bar end pin grease fitting(4) Left-hand equalizer bar end pin grease fitting

166 SEBU8593-01Maintenance SectionEqualizer Bar End Pins - Lubricate

Lubricate the equalizer bar end pins using thefollowing procedure.

1. Open the engine access door on the left-hand sideof the machine (if equipped). The equalizer barend pin lubrication fittings are along the left-handside of the engine forward of the ether cylinder.

2. Lubricate the right-hand equalizer bar end pinthrough right-hand equalizer bar end pin greasefitting (3).

3. Lubricate the left-hand equalizer bar end pinthrough left-hand equalizer bar end pin greasefitting (4).

Note: Some resistance should be detected whengrease is flowing to the equalizer bar end pin properly.If grease flows too easily, a problem such as a brokensupply line may exist. If no grease can be applied, anobstruction is interfering with grease flow. If either ofthese situations exists, perform an investigation todetermine the cause of improper grease flow.

4. When finished, close the engine access door onthe left-hand side of the machine (if equipped).

A visual confirmation of proper equalizer bar end pinlubrication can be made by examining the equalizerbar end pin relief valve.


Portion of left-hand track removed for visibilityLeft-hand equalizer bar end pin guard

Remove the two retaining bolts and washers thatsecure the equalizer bar end pin guard. Lift the guardfrom position to reveal the equalizer bar end pin reliefvalve.

Note: If necessary, clear dirt and debris from abovethe equalizer bar end pin guard before removal.

g02703659Illustration 223One of two vent holes in left-hand equalizer bar end pin relief valve

Clean any remaining debris from around the equalizerbar end pin relief valve after removal of the equalizerbar end pin guard. Grease will escape from the ventholes of the equalizer bar end pin relief valve oncethe chamber around the equalizer bar end pin is filledwith grease.

Note: Lubrication routes are separate for both theleft-hand and right-hand side equalizer bar end pins.Each side must be checked separately to ensure thatproper lubrication is occurring.

Note: Excessive wear will occur to the equalizer barend pin joint components if these components do notreceive adequate lubrication.


Ether Starting Aid Cylinder - Replace

i04562183

Ether Starting Aid Cylinder -ReplaceSMCS Code: 1456-510-CD


1. Open the left-hand engine access door of themachine. The ether cylinder is mounted inside thecompartment on the side of the engine.


2. Loosen retaining clamp (1). Remove old cylinder(2) by turning the cylinder counterclockwise.

3. Remove the old gasket. Install the new gasket.

4. Install the new cylinder. Turn the cylinder clockwiseand only hand tighten the cylinder. Tighten theclamp around the cylinder.


i04333268

Final Drive Oil - ChangeSMCS Code: 4050-044-FLV







1. Position one final drive so that oil level mark (1) ishorizontal. The drain plug (3) will point downward.

2. Remove oil filler plug (2).

3. Remove drain plug (3). Allow the oil to drain into asuitable container.

168 SEBU8593-01Maintenance SectionFinal Drive Oil Level - Check

4. Inspect the drain plug seal. Replace the drain plugseal if the drain plug seal is damaged.

5. Clean the drain plug and install the drain plug.

6. Fill the final drive with oil to the bottom of the fillerplug opening. See Operation and MaintenanceManual, “Capacities (Refill)”.

7. Inspect the condition of the seal of the filler plug.Replace the plug seal if the plug seal is damaged.Wipe the magnet in order to clean the plug. Installthe plug.

8. Repeat Step 1 to Step 7 in order to change the oilin the other final drive.

For additional information about final drive oil, seeSpecial Publication, SEBU6250, “Caterpillar MachineFluids Recommendations” or consult your Caterpillardealer.

i02790608

Final Drive Oil Level - CheckSMCS Code: 4050-535-FLV




1. Position one final drive so that oil level mark (2) ishorizontal with the oil filler plug (1).

2. Remove oil filler plug (1).

3. The oil level should be at the bottom of the fillerplug opening. Add oil, if necessary.

4. Wipe the magnet in order to clean the plug.

5. Install oil filler plug (1).

6. Repeat Step 1 to Step 5 in order to check the oillevel in the other final drive.

i04356911

Final Drive Oil Sample - ObtainSMCS Code: 3258-008; 4011-008; 4050-008;4050-SM; 4070-008; 4070-554-SM; 7542-008






Obtain the sample of final drive oil as close aspossible to the recommended sampling interval. Therecommended sampling interval is every 500 servicehours. In order to receive the full effect of S·O·Soil analysis, a consistent trend of data is importantto establishing a pertinent data history. Performconsistent oil samplings that are evenly spaced.

If the machine is operated under a high loadand/or under high temperature conditions,sample all fluids at the 250 hour interval.

1. Run the machine until operating temperature hasbeen reached. The sample must be at operatingtemperature in order to take an accurate sample.


Final Drive Seal Guard - Inspect/Clean


2. Position one final drive so that oil level mark (2) ishorizontal with the oil filler plug (1).

3. Remove oil filler plug.

4. The oil level should be at the bottom of the fillerplug opening. Obtain an oil sample. The use of asampling gun that is inserted into the sump is thepreferred method for obtaining a sample.

Note: Do not use the drain stream method fromoil drain plug (3) to obtain a sample of the finaldrive oil. A stream of dirty oil from the bottom of thecompartment will contaminate the sample. Likewise,never dip an oil sample from an oil container or poura sample from a used filter.

5. Wipe the magnet in order to clean the plug.

6. Install oil filler plug.

7. Repeat Step 2 to Step 6 in order to sample the oillevel in the other final drive.

Reference: Refer to, “Lubricant Viscosities” in theMaintenance Section of this manual for the correctfluid for your machine.

Reference: Refer to Special Publication, SEBU6250,“Caterpillar Machine Fluids Recommendations”,“S·O·S Oil Analysis” for information that pertainsto obtaining a sample of the final drive oil. Referto Special Publication, PEHP6001, “How To TakeA Good Oil Sample” for more information aboutobtaining a sample of the final drive oil.

i02211034

Final Drive Seal Guard -Inspect/Clean(If Equipped)SMCS Code: 4052-040; 4052-070

Note: The final drive seal guards may need to beinspected more frequently than the standard 500service hour interval when the machine is operatedin very severe applications. Adjust the interval, ifnecessary.


(1) Guard(2) Inspection cover

1. Remove the inspection cover (2) on the guard (1).

2. Inspect the condition of the final drive underneaththe guard. Inspect the final drive for debris orabrasive substances that are wrapped around thefinal drive such as cable or wire.

3. If the area inside the guard is packed with debrisor abrasive substances, remove guard (1) andclean the debris or abrasive substances from theguard and the final drive.

4. Install the guard (1) onto the final drive.

5. Install the inspection cover (2) on the guard (1).

Reference: Refer to Operation and MaintenanceManual, “Final Drive Seal Guard Packing - Replace(If Equipped)” for more information on the procedureto replace the packing.

170 SEBU8593-01Maintenance SectionFinal Drive Seal Guard Packing - Replace

i02777624

Final Drive Seal Guard Packing- Replace(If Equipped)SMCS Code: 4052-510

The design of the seal guard has a packing thatprevents debris from entering the area of theDuo-Cone Seal Gp. The close fit and tolerances limitthe size of the debris that can enter the labyrinth sealto 2 mm (0.079 inch). The labyrinth seal changesthe direction of the debris four times. Contact maybe made at the packing after the fourth time. Thepacking material is impregnated with silicone oil.Therefore, it is not necessary to fill the cavity for thepacking with grease. The packing is held in placeby retainers that can be removed. This allows thereplacement of the packing without removing the finaldrive. The packing has a split that allows the packingto be placed over the spindle.

Replacement of the Packing


(4) Bolt(5) Washer(6) Retainer

1. Remove bolts (4) and washers (5). Removeretainers (6).

g01387828Illustration 231Cross section view of seal guard

(3) Seal guard(6) Retainer(7) Inner packing(9) Outer packing(D) 2 mm (0.079 inch)

2. Inspect the packing and the seal guard forevidence of leaking through the packing. Removepacking (7) and (9) from seal guard (3). Oilleakage through the packing would indicateleakage of the Duo-Cone Seal Gp in the finaldrive. Inspect the Final Drive for oil leakagethrough the Duo-Cone Seal Gp. If oil is leakingthrough the seal, replace the Duo-Cone SealGp. Refer to the Service Manual.

Table 28

Required Parts

PartNumber

Qty Description

189-6244 2 Seal (packing)

129-1928 1 Grease

Note: Each final drive seal guard requires two189-6244 Seals (packing). The sections of packingare installed on top of each other in the groove ofthe seal guard.


Final Drive Seal Guard Packing - Replace


(7) Inner packing(8) Joint in the inner packing(A) Diameter (A)

3. Install inner packing (7). Place a thin film of129-1928 Grease on diameter (A). Stretch thepacking during installation. Smooth the packingand keep the packing uniform. Minimize the joint(8) at the ends of the inner packing (7).


(9) Outer packing(10) Joint in the outer packing(A) Diameter (A)(B) 180 degrees

4. Install the outer packing (9). Offset the joint inthe inner packing (8) and the outer packing(10) at 180 degrees. Stretch the packing duringinstallation. Smooth the packing and keep thepacking uniform. Minimize the joint (10) at theends of the outer packing (9).

172 SEBU8593-01Maintenance SectionFuel System - Prime

g00939660Illustration 234(4) Bolt(5) Washer(6) Retainer(9) Outer packing(10) Joint in outer packing(11) Joint in retainers(C) 90 Degrees from joint in outer packing to joint in retainers

Note: The joint (10) in the outer packing (9) must beoffset 90 degrees (C) to the joints (11) in the retainers(6).

5. Assemble retainers (6) to seal guard (3) withwashers (4) and bolts (5). The clearance at area(D) should be 2 mm (0.079 inch).

6. Repeat steps 3 through 5 in order to replace thepacking on the other final drive, if necessary.

i04338609

Fuel System - PrimeSMCS Code: 1250-548; 1258

If the engine does not start, air may be trapped in thefuel lines to the engine. Use the following procedurein order to purge air from the fuel lines.

1. Turn the key to the ON position. The electric fuelpriming pump is activated in this way.

2. Leave the key in the ON position for 2 minutes.This action allows the system to fully prime.

NOTICEDo not crank the engine continuously for more than30 seconds. Allow the starting motor to cool for twominutes before cranking the engine again.

3. Start the engine. If you cannot start the engine,the engine needs more priming. If the enginecontinues to misfire or to smoke, more priming isnecessary.

4. The fuel system will need to be primed when thefuel filters are replaced or fuel has been lost in thefuel supply system.

i04339009

Fuel System Primary Filter(Water Separator) - DrainSMCS Code: 1263-543

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. To help pre-vent possible injury, turn the start switch off whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.




NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over discon-nected fuel system component.


Fuel System Primary Filter - Clean/Replace

g02494956Illustration 235Electric Fuel Priming Pump, Primary Fuel Filter, and WaterSeparator Assembly

g02116797Illustration 236(1) Element(2) Bowl(3) Drain

Bowl (2) should be monitored daily for signs of water.If water is present, drain the water from the bowl.

1. Open drain (3). The drain is a self-ventilated drain.Catch the draining water in a suitable container.Dispose of the water properly.

2. Close drain (3).

NOTICEThe water separator is under suction during normalengine operation. Ensure that the drain valve is tight-ened securely to help prevent air from entering the fuelsystem.

i04339453

Fuel System Primary Filter -Clean/ReplaceSMCS Code: 1260-070; 1260-510

Personal injury or death can result from a fire.

Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.

Clean up all leaked or spilled fuel. Do not smokewhile working on the fuel system.

Turn the disconnect switch OFF or disconnect thebattery when changing fuel filters.




NOTICEDo not fill fuel filter with fuel before installing the fuelfilter. Contaminated fuel causes accelerated wear tofuel system parts.

174 SEBU8593-01Maintenance SectionFuel System Secondary Filter - Replace

g02495496Illustration 237(1) Left-hand cab entry door (reference only)(2) Fuel shutoff valve(3) Fuel shutoff valve handle

1. Locate fuel shutoff valve (2). The valve is insidethe enclosed compartment above the fender,forward and below the fuel tank fill cap on theleft-hand side of the machine.

2. Turn red-colored handle (3) to close valve.

3. Open left-hand engine access door.


4. Drain water separator bowl (5) into a suitablecontainer and remove the bowl from the bottomof the filter element. Clean the water separatorbowl and inspect the seal. If the seal is worn ordamaged, install a new seal.

5. Remove filter element (4). Properly discard thefilter element.

6. Clean the filter base. Be sure that all of the oldseal is removed.

7. Coat the seal of the new filter element with cleandiesel fuel.

8. Install the new filter element hand tight until theseal of the filter contacts the base. Note theposition of the index marks on the filter in relationto a fixed point on the filter base.

Note: There are rotation index marks on the filterthat are spaced 90 degrees or 1/4 of a turn awayfrom each other. When you tighten the filter, use therotation index marks as a guide.

Note: Tighten the filter according to the instructionsthat are printed on the filter. Use the index marks as aguide. For non-Caterpillar filters, use the instructionsthat are provided with the filter.

Note: A Caterpillar strap wrench, or another suitabletool, may be needed to turn the filter to the amountthat is required for final installation. Make sure thatthe installation tool does not damage the filter.

9. Coat the seal of the water separator bowl withclean diesel fuel. Install the water separator bowlto the filter element.

10. Turn red-colored handle (3) in order to open thefuel valve.

11.After the fuel filter is replaced, turn the key to theON position. Leave the key in the ON position for2 minutes. This action allows the system to fullyprime.

12.Start the engine and run the engine. Check filter(4) and water separator bowl (5) for leaks.

13.Close the engine access door.

i04340112

Fuel System Secondary Filter -ReplaceSMCS Code: 1261-510-SE

Personal injury or death can result from a fire.

Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.

Clean up all leaked or spilled fuel. Do not smokewhile working on the fuel system.

Turn the disconnect switch OFF or disconnect thebattery when changing fuel filters.


Fuel System Secondary Filter - Replace




NOTICEDo not fill fuel filters with fuel before installing them.Contaminated fuel will cause accelerated wear to fuelsystem parts.

Before you replace the secondary fuel filter element,replace the primary fuel filter element. See the Topic“Fuel System Primary Filter - Replace” in this manual.


(1) Left-hand cab entry door (reference only)(2) Fuel shutoff valve(3) Fuel shutoff valve handle

1. Locate fuel shutoff valve (2). The valve is insidethe enclosed compartment above the fender,forward and below the fuel tank fill cap on theleft-hand side of the machine .

2. Turn red-colored handle (3) to close valve.

3. Open left-hand engine access door.


4. Remove the secondary filter and the tertiary filter(4). Discard the fuel filters properly.

5. Clean the filter bases. Make sure that all of theold seals are removed.

6. Install the new filters. Coat the seals of the newfilters with clean diesel fuel.

7. Install the new filters by hand. When the sealscontact the base, tighten the filters according tothe instructions on the filters.

Rotation index marks are positioned on the filtersat 90 degree intervals. Use these rotation indexmarks as a guide when you tighten the filters.

8. Turn red-colored handle (3) in order to open thefuel valve.

9. After the fuel filters are replaced, turn the key tothe ON position. Leave the key in the ON positionfor 2 minutes. This action allows the system tofully prime.

10.Start the engine and run the engine. Check filters(4) for leaks.

11.Close the engine access door.

176 SEBU8593-01Maintenance SectionFuel Tank Cap Filter and Strainer - Replace/Clean

i04341911

Fuel Tank Cap Filter andStrainer - Replace/CleanSMCS Code: 1273-070-STR; 1273-070-Z2


(1) Fuel tank cap with filter and strainer(2) Fast fill adapter connection fitting

The fuel tank is located on the rear of the machine.The filler cap (1) is on the left side of the machinenext to the ROPS.


Detailed view of fuel tank cap components

1. Lift lever (5) in order to remove the fuel tank fillercap. Turn the lever counterclockwise until thelever stops. Lift the cap straight up in order toremove the cap.

2. Remove the fuel strainer from the filler neck.

3. In order to replace the filter assembly, remove twoscrews that secure filter assembly (4) to the fuelcap. Remove filter assembly (4), valve (3), andthe gaskets.

4. Wash the cap and the strainer in a clean,nonflammable solvent.

5. Inspect the tank cap seal. If the seal is damaged,replace the seal.

6. Replace the filter assembly, the valve, the gaskets,and the screws. Use a 9X-2205 Cap Filter Kit.

7. Install the strainer.

8. Install the fuel cap. Rotate the fuel cap clockwiseuntil three tabs (7) drop into the slots in theadapter. Rotate lever (5) clockwise until the leverstops. Lower lever (5) over locking tab (6).

Fast Fill Fuel Adapter (If Equipped)See illustration 241.

Machines that are equipped with a fast fill fuel adapter(2) have identical fuel caps as systems without afast fill fuel adapter. Use the same procedure forchanging the filter in the two systems.

i04342173

Fuel Tank Water and Sediment- DrainSMCS Code: 1273-543-M&S






Fuses and Circuit Breakers - Replace/Reset

The drain valve is under the fuel tank at the rear ofthe machine.

1. Open the drain valve. Allow the water and thesediment to drain into a suitable container.

2. Close the drain valve.

i04357075

Fuses and Circuit Breakers -Replace/ResetSMCS Code: 1417-510; 1420-529; 1420

Fuses – These fuses protect the electricalsystem from damage that is caused byoverloaded circuits. Replace a fuse if the

element separates. The circuit should be checkedand repaired if the element separates with a newfuse. The fuses are in the operator compartment.

NOTICEReplace the fuses with the same type and size only.Otherwise, electrical damage can result.

If it is necessary to replace fuses frequently, an electri-cal problem may exist. Contact your Caterpillar dealer


The fuse panel is behind the access cover that isbelow the left armrest of the operator seat.


178 SEBU8593-01Maintenance SectionHorn - Test

Table 29

Primary Fuse Panel

A B C D

1 SecondBrake 10A

AuxiliaryPower 15A

Powertrain

ECM 15A

Imp ECM15A

2 Prod Link10A

EngineECM 15A

Navigator10A

ConvPower 20A

3 FenderFloods 15A

4 15A

Fuel PrimeRelay

Fender FloodsRelay

5Rip/ImplControl15A

Fuel TankRipper

Flood 15A

R ROPS/HID 15A

Accugrade15A

6 Blower15A

Wipers15A

VoltMonitor10A

WakeupAuxiliaryPower 15A

7 10A

8 15A

Spare Relay Dual Starter Relay

9Cab

Pressure10A

10 Cyl Floods15A

CyclinderFloods Relay Pressurizer Relay

11 ROPSFloods 15A

12 Horn 10A

FWD ROPSFloods Relay Ingress Relay

13 Seat 15A KeySW10A

RemoteControl15A

Spare 15A

14 NozzleHeat 15A

Advis/InstrCluster15A

Spare15A

10AConverter15A

15 Condns215A

Accug215A

EngineECM 15A Spare 15A

16 Condns115A

Eng/Xmsn/Monitor10A

Spare15A Spare

i02054663

Horn - TestSMCS Code: 7402-081

Test the horn on a daily basis. Press downward onthe horn button in order to sound the horn. If the horndoes not sound, make the necessary repairs beforeyou operate the machine.

i04343851

Hydraulic System FilterScreens - CleanSMCS Code: 5068

The screen should be cleaned especially when oneof the following situations have occurred:

• Cleaning of the Hydraulic Tank

• Failure of the Fan Motor

• Failure of the Fan Pump

• Failure of the Implement Pump

• Failure of the Steering Motor

• Failure of the Steering Pump

• PCR (Engine Overhaul)

1. Park the machine on a level surface. Lower thework tool to the ground. Engage the parking brake.

2. Turn the engine start switch key to ON.

3. Move the hydraulic control levers through all ofthe positions in order to release pressure.

4. Turn the engine start switch key to OFF.


Hydraulic System Filter Screens - Clean

At operating temperature, the hydraulic tank is hotand under pressure.

Hot oil and components can cause personal in-jury. Do not allow hot oil or components to contactskin.

Before removing the filler cap, press the valve re-lief button on the hydraulic tank in order to relievethe tank pressure.

Remove the filler cap only when the engine isstopped and the filler cap is cool enough to touchwith your bare hand. Remove the filler cap slowlyin order to relieve any remaining pressure.

g01943757Illustration 246Front view of the hydraulic tank

(1) Filler cap(2) Pressure/vacuum breaker valve(3) Oil level sight gauge(4) Drain plug

5. Press the button on pressure/vacuum breakervalve (2) in order to relieve any tank pressure.Slowly remove filler cap (1).

g01943758Illustration 247Top view of the hydraulic tank

g01943759Illustration 248Left-hand (inboard) view of the hydraulic tank(5) Implement return port(6) Hydraulic tank access cover(7) Case drain return port(8) Suction port

6. Drain the hydraulic oil tank at drain (4).

Reference: For the correct procedure, refer toOperation and Maintenance Manual, “HydraulicSystem Oil - Change”.

7. Unbolt hydraulic tank access cover (6).


Cutaway view of interior of hydraulic tank

(9) Case drain return bypass valve and screen assembly(10) Implement return screen

8. Remove implement return screen (10). Clean thescreen with clean, nonflammable solvent.

9. Remove case drain return bypass valve andscreen assembly (9). A spring and valvemechanism are housed within the screen. Takecare to remove all components for cleaning andinspection. Clean all components with clean,nonflammable solvent.

180 SEBU8593-01Maintenance SectionHydraulic System Oil - Change

10. Install the case drain valve mechanism, spring,and screen being careful that components areinstalled properly. Make certain that the valvemechanism is seated properly, and that the valvemechanism and spring are not bound up and canoperate freely.

11. Install the implement return screen.

12.Replace hydraulic tank access cover (6).

13. Fill the hydraulic tank.

Reference: For the correct procedure, refer toOperation and Maintenance Manual, “HydraulicSystem Oil - Change”.

14.Replace filler cap (1).

i04562465

Hydraulic System Oil - ChangeSMCS Code: 5050-044



Remove the filler cap only when the engine isstopped, and the filler cap is cool enough to touchwith your bare hand. Remove the filler cap slowlyto relieve pressure.




Operate the machine in order to warm the oil.

Park the machine on level ground. Lower thebulldozer blade and the ripper to the ground andapply slight downward pressure. Engage the parkingbrake and stop the engine.

g02500237Illustration 250Hydraulic oil tank located above right-hand fender(1) Filler cap(2) Pressure/vacuum breaker valve(3) Oil level sight gauge(4) Drain valve(5) Pipe plug

1. Press the button on pressure/vacuum breakervalve (2) in order to relieve any tank pressure.Slowly remove filler cap (1).

2. Remove pipe plug (5) that is screwed into drainvalve (4). Hold the drain valve with a wrench, ifnecessary, to keep the valve from turning whileremoving the pipe plug.

3. Install a 12.7 mm (0.5 inch) drain pipe into thedrain valve. The pipe must have 1/2 - 14 NPTFthreads. Clamp a hose to the pipe in order todirect the oil into a suitable container.

4. Open the drain valve by turning the square stemthat is on top of the valve. The notch found in thestem is a reference that is aligned with the internalopening of the valve ball. Allow the oil to drain intoa suitable container.

5. Remove the filler strainer inside the filler tube.Wash the filler strainer and the filler cap in cleannonflammable solvent. Install the filler strainerinside the filler tube.

6. Close the drain valve. Remove the drain pipe anddrain hose from the valve. Clean the pipe plug andinstall the pipe plug.

7. Change the hydraulic system case drain oil filter.See the Operation and Maintenance Manual,“Hydraulic System Oil Filter - Replace”.

8. Fill the hydraulic oil tank. See the Operation andMaintenance Manual, “Capacities (Refill)” in orderto determine the amount of hydraulic oil that isneeded to fill the hydraulic oil tank.


Hydraulic System Oil Filter - Replace

9. Inspect the filler cap gasket. Replace the gasket ifdamage or wear is evident.


11.Start the engine. Run the engine for a fewminutes.


12.Maintain the oil level to the “FULL” mark in sightgauge (3). Check with the attachments on theground and with oil cold (ambient temperature).Add oil, if necessary.

13.Stop the engine.

For additional information about hydraulic system oil,see Operation and Maintenance Manual, SEBU6250,“Caterpillar Machine Fluids Recommendations” orconsult your Caterpillar dealer.

i04348189

Hydraulic System Oil Filter -ReplaceSMCS Code: 5068-510







Case Drain Oil Filter

g02503797Illustration 252Front angle view of hydraulic tank

(1) Filler cap(2) Filter element assembly(3) Pressure/vacuum breaker valve(4) Oil level sight gauge

182 SEBU8593-01Maintenance SectionHydraulic System Oil Level - Check

g02503136Illustration 253Filter element assembly removed from tank and disassembled(5) Cover retaining nut and washer (four sets)(6) Filter cover(7) Cover o-ring seal(8) Retaining stud(9) Filter element(10) Filter retainer(11) Filter retainer o-ring seal(12) Locknut

1. Press the button on pressure/vacuum breakervalve (3) on top of hydraulic oil tank in order torelieve any tank pressure. Slowly remove fillercap (1).

2. Remove filter cover retaining nuts and washers(5).

3. Remove filter element assembly (2).

4. Remove locknut (12) and retainer (10) from stud(8). Filter retainer o-ring seal (11) will remaininstalled in the retainer groove. The seal isshown as removed from the retainer for clarity ofillustration only.

5. Remove filter element (9). Properly discard thefilter element.

6. If stud (8) was loosened from cover (6) during theremoval of the retaining nut, tighten the stud to atorque of 35 ± 7 N·m (25.9 ± 4 lb ft).

7. Wash the cover and the retainer in clean,nonflammable solvent.

8. Inspect cover seal (7) and filter retainer seal (11).Replace the seals if the seals are damaged.

9. Install a new filter element (9).

10. Install the clean retainer and the locknut. Tightenthe locknut to a torque of 10 ± 1.5 N·m (7 ± 1 lb ft).

11. Install the filter assembly. Tighten the coverretaining nuts to a torque of 45 ± 7 N·m(32 ± 5 lb ft).

12.Maintain the hydraulic oil to the “FULL” mark inthe oil level sight gauge (4).

13. Install the hydraulic tank filler cap.

i04349199

Hydraulic System Oil Level -CheckSMCS Code: 5056-535-FLV; 7479



Remove the filler cap only when the engine isstopped, and the filler cap is cool enough to touchwith your bare hand. Remove the filler cap slowlyin order to relieve pressure.

Lower the bulldozer and the ripper to the ground.Place the ripper shanks in the vertical position.

The hydraulic tank is on the right-hand side of themachine above the fender.

g01042594Illustration 254Oil level sight gauge located on front of hydraulic oil tank

1. Maintain the oil level to the “FULL” mark in thesight gauge. Check the oil level when the oil iscold (ambient temperature). Verify that the oil levelis below the “FULL” mark before you remove thefiller cap.

2. If the hydraulic system requires additional hydraulicoil, press the button on the pressure/vacuumbreaker valve to relieve any tank pressure. Slowlyremove the filler cap. Add oil through the filler tube.


Hydraulic System Oil Sample - Obtain

3. Clean the filler cap and install the filler cap.

i04347509

Hydraulic System Oil Sample- ObtainSMCS Code: 5095-008






g02502498Illustration 255(1) Left-hand cab entry door (reference only)(2) Hydraulic oil sampling valve(3) Steering charge filter (reference only)

Obtain a sample of the hydraulic oil from samplingvalve (2). The sampling valve is located on the baseof the steering charge filter (3). The filter is insidethe enclosed compartment forward and below thefuel tank fill cap on the left-hand side of the machineabove the fender. Remove the protective cap from theoil sampling valve that is above the steering chargefilter. Refer to Special Publication, SEBU6250, “S·O·SOil Analysis” for information that pertains to obtaininga sample of the oil. Refer to Special Publication,PEHP6001, “How To Take A Good Oil Sample” formore information about obtaining a sample of the oil.

For additional information about hydraulic systemoil, see Special Publication, SEBU6250, “CaterpillarMachine Fluids Recommendations” or consult yourCaterpillar dealer.

i04561553

Indicators and Gauges - TestSMCS Code: 7450-081; 7490-081

If the action alarm does not sound during this testor machine monitoring displays are not function-ing, do not operate the machine until the causehas been corrected. Machine operation with faultyaction alarms or displays could result in injury ordeath as any Warning Category 3 notifications willnot be relayed to the operator.

Check the operation of the Monitoring System.Observe the self test when you start the engine.

The system performs an automatic self test whenyou turn the engine start switch to the ON position.

The self test verifies that the monitoring panel andthe display modules are operating properly. The selftesting feature verifies that the display module isproperly operating.

The internal circuits, the indicators, and the gaugesare automatically checked.

184 SEBU8593-01Maintenance SectionLift Cylinder Yoke Bearings - Lubricate

g02727437Illustration 256Gauge and instrument module

The operator must observe the indicators and thegauges in order to determine whether gauge module(1), action light (2), alert indicators (3), and the digitaldisplay (4) are operating properly. The self test lastsfor approximately 3 seconds.

During the self test, all status indicators on theinstrument module light.

The digital display shows the following readouts:

• Initial part number of the instrument module

• 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 quad gauge point upward. Then,the pointers point to the left. Then, the pointers pointto the right. Then, the pointers point to the finalposition.

• The readout of the gear shows “**”.

• The speed readout shows “888”, “MPH”, and“km/h”.

• The rear action light “ON then OFF”

• The forward action light stays illuminated.

• The action alarm sounds once.

The monitoring panel is then in the normal operatingmode.

If the above tests are not correctly completed, thesystem will not function in the normal operatingmode. Consult your Caterpillar dealer for an electricalsystem check. Any repairs must be made before youstart the engine.

Turn on all of the machine lights. Check for properoperation. Sound the forward horn.

Stop the engine.

Make any necessary repairs before you operate themachine.

i04349450

Lift Cylinder Yoke Bearings -LubricateSMCS Code: 5102-086-BD


The grease fittings are located on the left front sideof the machine and on the right front side of themachine. Lubricate the bearings by applying greaseto the two fittings. Use MPGM Grease.

SEBU8593-01 185Maintenance SectionOil Filter - Inspect

i02106227

Oil Filter - InspectSMCS Code: 1318-507; 3067-507; 5068-507

Inspect a Used Filter for Debris


The element is shown with debris.

Use a filter cutter to cut the filter element open.Spread apart the pleats and inspect the element formetal and for other debris. An excessive amount ofdebris in the filter element can indicate a possiblefailure.

If metals are found in the filter element, a magnet canbe used to differentiate between ferrous metals andnonferrous metals.

Ferrous metals can indicate wear on steel parts andon cast iron parts.

Nonferrous metals can indicate wear on thealuminum parts of the engine such as main bearings,rod bearings, or turbocharger bearings.

Small amounts of debris may be found in the filterelement. This could be caused by friction and bynormal wear. Consult your Caterpillar dealer in orderto arrange for further analysis if an excessive amountof debris is found.

Using an oil filter element that is not recommendedby Caterpillar can result in severe engine damageto engine bearings, to the crankshaft, and to otherparts. This can result in larger particles in unfilteredoil. The particles could enter the lubricating systemand the particles could cause damage.

i04337689

Pivot Shaft Oil Level - CheckSMCS Code: 4153-535-FLV



g02493356Illustration 259Pivot shaft oil level reservoir cap and oil level gauge

1. Open angled access cover (1) that is rearward ofthe left-hand engine access door.

2. Loosen cap/oil level gauge (2) by turning thehandle counter-clockwise enough to lift out.

3. Proper reservoir oil level is maintained by addingoil through the reservoir opening. Maintain theoil level to the FULL mark on oil level gauge (2).Do not overfill. Overfilling can cause hot oil tooverflow the reservoir .

4. Install the cap/oil level gauge in the reservoiropening and tighten by turning clockwise untilsnug.

Note: The initial fill of pivot shaft may trap air in thetube. The level of the oil may fall as air escapes.The reservoir must be filled several times to remainconsistently full.

186 SEBU8593-01Maintenance SectionPower Train Breather - Clean

g01434353Illustration 260(3) Filler plug for pivot shaft compartment(4) Drain plug for pivot shaft compartment

Check for seal leakage at the pivot shaft retainer.The pivot shaft retainer is located on the main framecase. If there is any sign of seal leakage, refer tothe appropriate Service Manual or consult yourCaterpillar dealer for repairs.

Note: If disassembly is required, fill at filler plug (3),and at the oil reservoir after completion of repair.

i03649020

Power Train Breather - CleanSMCS Code: 3030-070-BRE


Top viewSome components are removed for clarity.

1. Open the floorplate that is inside of the cab. Thebreather attaches to the tube from the torqueconverter to the transmission case. Unscrew andremove the breather.

2. Clean the breather in clean, nonflammablesolvent.

3. Install the breather and close the cover.

i04556904

Power Train Oil - ChangeSMCS Code: 4000-044-OC






Operate the machine in order to warm the powertrain oil. The machine must be level. Lower theattachments with slight down pressure.

Engage the parking brake switch. Stop the engine.

1. Power train oil is drained from beneath themachine.


Power Train Oil - Change

g02724463Illustration 262Partial view of machine underside from rear of machine

(1) Transmission drain valve access cover (if equipped)(2) Bevel gear case drain plug(3) Bottom guard beneath torque converter (if equipped)

2. Remove drain plug (2) from the bevel gear case.An ecology valve will keep the oil from drainingout of the bevel gear case. Install a 4C-8563Swivel into the valve. Clamp a hose to the swivel.A 25.4 mm (1 inch) pipe and hose can be used.Use a 25.4 mm (1 inch) pipe with 1-11 1/2 NPTFthreads. Turn the pipe, if used, by hand only.

3. Turn the swivel or pipe clockwise in order to openthe internal drain valve. Allow the oil to drain into asuitable container.


Rear view of bottom of torque converter(4) Drain valve housing(5) Pipe plug(6) Drain valve

4. Lower bottom guard (if equipped) (3) beneath thetorque converter to access the torque converterdrain. Remove pipe plug (5) from the bottom ofdrain valve housing (4) on the torque converter.Install a 12.7 mm (0.5 inch) pipe into the drainvalve housing. Use a 12.7 mm (0.5 inch) pipe with1/2-14 NPTF threads.

Note: Refer to Disassembly and Assembly,UENR0029, “D9T Track-Type Tractor EngineSupplement” for more information on lowering thebottom guard.

5. Clamp a hose to the pipe in order to direct the oilinto a suitable container.

6. Open drain valve (6) and drain the oil into asuitable container.

g02724484Illustration 264Transmission drain valve at rear of machine (access coverremoved, if equipped)(7) Transmission valve housing(8) Pipe plug(9) Drain valve

7. Remove access cover (1) for the transmissiondrain valve. The access cover (if equipped) isfound at the rear of the machine.

8. The transmission drain valve is the same typeas the torque converter drain valve. Removepipe plug (8) from drain valve housing (7) of thetransmission. Install a 12.7 mm (0.5 inch) pipeinto the transmission drain valve housing. Use a12.7 mm (0.5 inch) pipe with 1/2-14 NPTF threads.

9. Clamp a hose to the pipe in order to direct the oilinto a suitable container.

10.Open transmission drain valve (9) and drain theoil into a suitable container.

11.Close the drain valve on the torque converter.Close the drain valve on the transmission.

188 SEBU8593-01Maintenance SectionPower Train Oil - Change

12.Remove the hoses and remove the pipes from thedrains. Clean the oil drain pipe plugs and installthe oil drain pipe plugs.

13. Install any access covers or bottom guards thatwere removed or lowered to access the drainvalves.

14.Remove the swivel or remove the pipe from thedrain in the bevel gear case. The drain valve willclose. Clean the oil drain plug and install the oildrain plug.

15.Change the filter elements. See Operation andMaintenance Manual, “Power Train Oil Filters -Replace”.


Power train oil filler cap

16. Locate power train oil filler (10) cap. The powertrain filler cap is in the compartment below the cabfresh air filter on the left-hand side of the machine.

17.Remove the power train oil filler cap.

18.Add oil. To determine the correct amount ofoil, see Operation and Maintenance Manual,“Capacities (Refill)”.

19.Clean the power train oil filler cap and install thepower train oil filler cap.


20. Locate power train oil level gauge (11). The powertrain oil level gauge is located behind the angledaccess cover that is rearward of the left-handengine access door.


21.Maintain the oil level within operating range (X),between the “ADD” mark and the “FULL” mark onthe oil level gauge.

a. When the engine is stopped and the oil is cold(ambient temperature), maintain the oil levelon the “ENGINE STOPPED COLD OIL” sideof the oil level gauge.

b. When the engine is running and the oil is hot(operating temperature), maintain the oil levelon the “ENGINE LOW IDLE HOT OIL” side ofthe oil level gauge.

High Speed Oil Change (IfEquipped)Open the engine access door on the left-hand side ofthe machine. Swing down the lower guard assemblyto reveal the high speed oil change connectionfittings.


Power Train Oil Filters - Replace

g02724496Illustration 268(12) Engine high speed oil change connection fitting (if equipped,

reference only)(13) Power train high speed oil change connection fitting (if

equipped)

Power train high speed oil change connectionfitting (if equipped) (13) can be used with additionalequipment to change the power train oil. The highspeed oil change removes oil only from the sump inthe bevel gear case. The high speed oil change doesnot remove oil from the torque converter or from thetransmission case. The filters will still need changed.See Operation and Maintenance Manual, “PowerTrain Oil Filter - Replace”.

i04357412

Power Train Oil Filters -ReplaceSMCS Code: 3067-510






Two filters are located under the fuel tank. The fueltank is on the rear of the machine. There is one filterunder each side of the fuel tank.


1. Remove drain plug (1) in order to remove a smallamount of oil from each filter housing (2). Use awrench in order to remove the filter housings.

2. Remove the filter elements. Properly discard thefilter elements.

3. Clean the filter element housings and clean thefilter bases (3) with a clean cloth.

4. Inspect the seals. If the seals are damaged,replace the seals.

5. Install the new filter elements. Install the filterelement housings. Install the filter housing drainplugs.

6. Start the engine.



190 SEBU8593-01Maintenance SectionPower Train Scavenge Screen - Clean



a. When the engine is stopped and the oil is cold(ambient temperature), maintain the oil level onthe “ENGINE STOPPED COLD OIL” side of theoil level gauge. This method should be used asreference only, before the engine is started.

b. When the engine is running and the oil is hot(operating temperature), maintain the oil levelon the “ENGINE LOW IDLE HOT OIL” side ofthe oil level gauge. This procedure is the onlyaccurate way to check the oil level.

Note: When you are operating the machine onsevere slopes, the quantity of oil in the power traincan be increased up to 10 percent. When you areoperating with the increased oil quantity, prolongedoperation in some machines can cause high powertrain oil temperatures. After the work on the severeslopes has been completed, drain the excessive oilquantity from the bevel gear case.

g02505777Illustration 272Power train oil filler cap

9. Locate power train oil filler cap (4). The powertrain filler cap is in the compartment below the cabfresh air filter on the left-hand side of the machine.

10. If necessary, remove the power train oil filler capand add oil.

11.Clean the power train oil filler cap and install thepower train oil filler cap.

i03656528

Power Train Scavenge Screen- CleanSMCS Code: 3030-070-MGS



When you change the transmission oil, clean thescavenge screen. Drain the oil before you removeany screens.


Note: Ecology drains have been provided. Anecology drain drains off the oil from the sump of theplanetary transmission. Remove the bottom plug.Install a pipe with 1/2-14 NPTF threads and a rubberhose. Drain the sump by backing out the valve untilthe oil begins to drain.

1. Remove cover (1), the seal, and transmissionscavenge screen (2) from the bottom of thetransmission.

2. Wash the screen in a clean, nonflammablesolvent.

3. Inspect the seal. If the seal is damaged, replacethe seal.

4. Install transmission scavenge screen (2), the sealand cover (1) on the transmission.

5. Install the bottom guard.

Reference: See Operation and MaintenanceManual, “Power Train System Oil and Screens -Change/Clean” in order to fill with oil.


Power Train System Oil And Screens - Change/Clean

i04560933

Power Train System Oil AndScreens - Change/CleanSMCS Code: 3067-070; 3067-510







Drain the Oil and Change theTransmission Oil Filter ElementsOperate the machine in order to warm the powertrain oil. The machine must be level. Lower theattachments with slight down pressure.

See the Operation and Maintenance Manual, “PowerTrain Oil Filter - Replace” in this manual for theprocedure to change the transmission filters.

g02486238Illustration 274(1) Engine high speed oil change connection fitting (if equipped,

reference only)(2) Power train high speed oil change connection fitting (if

equipped)

Open the engine access door on the left-hand side ofthe machine. Swing out the lower guard assembly toreveal power train high speed oil change connectionfitting (if equipped) (2).

Use a 126-7538 Nozzle if the machine is equippedwith the high speed oil change arrangement. Thisarrangement removes oil from the sump in the bevelgear case. The high speed oil change does notremove oil from the torque converter or from thetransmission case.


1. Remove the plug from the drain in the bevel gearcase. Install a 4C-8563 Swivel into the valve.Clamp a hose to the swivel. A 25.4 mm (1 inch)pipe and hose can be used. Use a 25.4 mm(1 inch) pipe with 1-11 1/2 NPTF threads. Do nottighten the pipe.

2. Turn the swivel or pipe clockwise in order to openthe internal drain valve. Allow the oil to drain into asuitable container.

3. Lower the rear bottom guard that is below thetorque converter.

192 SEBU8593-01Maintenance SectionPower Train System Oil And Screens - Change/Clean

g02726847Illustration 276Rear view of torque converter

4. Remove plug (3) from the drain valve in the torqueconverter. Install a 12.7 mm (.5 inch) pipe into thedrain valve. Use a 12.7 mm (0.50 inch) pipe with1/2-14 NPTF threads.

5. Clamp a hose to the pipe in order to drain the oilinto a suitable container.



Rear view of transmission

7. Access drain valve body (5) for the transmissionat the rear of the machine, as shown.

8. Remove plug (7) from the bottom of drain valvebody in the transmission. Install a 12.7 mm(.5 inch) pipe into the drain valve body. Usea 12.7 mm (0.50 inch) pipe with 1/2-14 NPTFthreads. Clamp a hose to the pipe in order to drainthe oil into a suitable container.


10.Change the filter element in the transmissionoil filters that are located at the rear of themachine. See the Topic “Transmission System OilFilter-Replace” in this manual.

11.Close drain valve (4) in the torque converter.Close drain valve (6) in the transmission case.

12.Remove the hoses and remove the pipes fromthe drains.

13.Remove the swivel or remove the pipe from thedrain in the bevel gear case. The drain valve willclose.

14.Clean the oil drain plugs and install the oil drainplugs.

Clean ScreensScreens should be removed and cleaned when theoil is drained.

1. Drain the oil into a suitable container beforeremoving any screen.

2. Remove the covers. Remove the screens.

3. Clean the three screens in clean, nonflammablesolvent.

4. Install the screens. Install the covers.

Torque Converter


1. Remove the bolts and drain valve body (9) fromthe torque converter, as shown.

2. Remove torque converter screen (10). Inspect thetorque converter screen for debris accumulation


Power Train System Oil And Screens - Change/Clean

3. Clean the torque converter screen in clean,nonflammable solvent.

4. Install the torque converter screen and the torqueconverter drain valve body.

Main Suction Screen

Access to the main power train suction line screen ismade from inside the operator cab of the machine.


View of main power train suction line screen assembly throughaccess opening in floor of operator platform(11) Main power train suction line screen assembly

Use the following procedure to service the mainpower train suction line screen.

1. Remove the operator platform floor mat andoperator platform access covers that are in front ofthe operator seat. Power train suction line screenassembly (11) is accessed beneath the operatorplatform.

g02726936Illustration 280Expanded view of main power train suction line screen assemblycomponents

(12) Retaining nuts and washers(13) Housing top cover(14) Wave washer(15) Thrust washer(16) Magnet tube(17) Magnets(18) Suction screen(19) Suction screen housing(20) Magnet tube assembly

2. Remove four sets of nuts and washers (12) thatretain suction screen housing top cover (13).Then, remove the suction screen housing topcover.

3. Remove wave washer (14) and thrust washer (15).

4. Carefully lift magnet tube assembly (20) from theinside of suction screen (18). Inspect magnets(17) for debris accumulation.

Note: Complete cleaning of the magnets is difficult.Caterpillar recommends that the magnets bereplaced if contaminated with debris. Magnets (17)can be removed from magnet tube (16) and bereplaced with new magnets purchased individuallyfrom your Cat dealer. Magnet tube assembly (20),which includes all five magnets is also available fromyour Cat dealer as a replacement part.

5. Carefully lift suction screen (18) from suctionscreen housing (19), and inspect the suctionscreen for debris accumulation.

6. Clean the suction screen in clean, nonflammablesolvent.

7. Install the suction screen in the suction screenhousing.

194 SEBU8593-01Maintenance SectionPower Train System Oil And Screens - Change/Clean

8. Install a new magnet tube assembly (if replaced),or the old magnet tube with new magnets installed(if replaced) inside the suction screen.

9. Install the thrust washer, then the wave washeron top of the suction screen and the magnet tubeassembly.

10. Install the suction screen housing top coverand secure with the retaining nuts and washers.Tighten the cover retaining nuts to a torque of35 ± 5 N·m (26 ± 4 lb ft).

Transmission Scavenge Screen


1. Remove drain valve body (21) from thetransmission.

2. Remove transmission scavenge screen (22).Inspect the transmission scavenge screen fordebris accumulation.

3. Clean the transmission scavenge screen in clean,nonflammable solvent.

4. Install the transmission scavenge screen and thetransmission drain valve body.

Fill With Oil



2. Remove the oil fill cap and fill the bevel gear casewith oil. See Operation and Maintenance Manual,“ Capacities (Refill)”.

Note: The power train may be filled with oil by usingoil filler cap (23), or the power train high speed oilchange connection fitting (2).

3. Fill the bevel gear case with oil. See Operationand Maintenance Manual, “ Capacities (Refill)”.



5. Maintain the oil level within operating range,between the “ADD” mark and the “FULL” markon the oil level gauge. See Operation andMaintenance Manual, “Power Train System OilLevel - Check” for more information.

6. Clean oil filler cap (23). Install the oil filler cap (ifremoved).

7. Install the rear bottom guard.

For additional information about transmissionsystem oil, see Operation and MaintenanceManual, SEBU6250, “Caterpillar Machine FluidsRecommendations” or consult your Caterpillar dealer.


Power Train System Oil Level - Check

i04352037

Power Train System Oil Level -CheckSMCS Code: 3030-535-FLV







a. When the engine is stopped and the oil is cold(ambient temperature), maintain the oil level onthe “ENGINE STOPPED COLD OIL” side of theoil level gauge. This method should be used asreference only, before the engine is started.

b. When the engine is running and the oil is hot(operating temperature), maintain the oil levelon the “ENGINE LOW IDLE HOT OIL” side ofthe oil level gauge. This procedure is the onlyaccurate way to check the oil level.

Note: When you are operating the machine onsevere slopes, the quantity of oil in the power traincan be increased up to 10 percent. When you areoperating with the increased oil quantity, prolongedoperation in some machines can cause high powertrain oil temperatures. After the work on the severeslopes has been completed, drain the excessive oilquantity from the bevel gear case.

g02505777Illustration 286Power train oil filler cap


4. If necessary, remove the power train oil filler capand add oil.

5. Clean the power train oil filler cap and install thepower train oil filler cap.

i04352389

Power Train System Oil Sample- ObtainSMCS Code: 3080-008



196 SEBU8593-01Maintenance SectionRadiator Core - Clean




Obtain the sample of the power train oil as closeas possible to the recommended sampling interval.The recommended sampling interval is every 500service hours. In order to receive the full effect ofS·O·S oil analysis, a consistent trend of data must beestablished. In order to establish a pertinent historyof data, perform consistent oil samplings that areevenly spaced.

1. Start the engine. Park the machine on levelground. Engage the parking brake.

2. Lower all implements to the ground. After loweringall implements to the ground, deactivate theimplement controls with the implement lockoutswitch.

3. Locate the power train oil sampling valve. Thesampling valve is located below the fuel tank atthe rear of the machine on the left-hand powertrain oil filter base .


Power train oil sampling valve

4. Remove the protective cap from the samplingvalve.

5. Obtain a sample of transmission oil. Refer toSpecial Publication, SEBU6250, “S·O·S OilAnalysis” for information that pertains to obtaininga sample of the transmission oil.

6. After you take a sample, remove the cap withthe tube and the probe from the bottle. Properlydispose of the cap with the tube and the probe.Install the sealing cap that is provided with169-8373 Fluid Sampling Bottle.

7. Replace the protective cap on the oil samplingvalve.

8. Stop the engine.

For additional information about transmission systemoil, see Special Publication, SEBU6250, “CaterpillarMachine Fluids Recommendations” or consult yourCaterpillar dealer.

i04556798

Radiator Core - CleanSMCS Code: 1353-070; 1805-070; 1810-070


Clean the radiator core with compressed air. You mayneed to use water in order to remove debris.

Reference: See Operation and Maintenance Manual,“Cooler Cores and A/C Condenser - Clean” forinformation on a typical cleaning procedure.


Radiator Pressure Cap - Clean/Replace

i04352773

Radiator Pressure Cap -Clean/ReplaceSMCS Code: 1353-070-Z2; 1353-510-Z2

Pressurized system: Hot coolant can cause seri-ous burn. To open cap, stop engine, wait until ra-diator is cool. Then loosen cap slowly to relievethe pressure.

g02508236Illustration 289Coolant filler cap

1. The coolant filler cap is located beneath theaccess cover on top of the hood, forward of theengine air precleaner. Open the cover on top ofthe hood to access the filler cap.

2. Slowly remove the filler cap in order to relievesystem pressure.

3. Inspect the filler cap for damage, for deposits, orfor foreign material. Clean the filler cap with aclean cloth. Replace the filler cap if the filler cap isdamaged.


i04562120

Recoil Spring CompartmentOil Level - CheckSMCS Code: 4158-535-OC




1. Remove all of the debris around the cover plateon the top of the track roller frame.

2. Remove the cover plate for the oil filler. Observethe level of the oil.


198 SEBU8593-01Maintenance SectionRefrigerant Dryer - Replace

3. Maintain the oil level above the top of the trackadjusting cylinder (1). Do not fill the oil above thetrack adjustment valve (2).

4. Install the cover plate.

5. Repeat the procedure for the other recoilcompartment.

i04556829

Refrigerant Dryer - ReplaceSMCS Code: 7322-510; 7322-535

Personal injury can result from contact with refrig-erant.

Contact with refrigerant can cause frost bite. Keepface and hands away to help prevent injury.

Protective goggles must always be worn when re-frigerant lines are opened, even if the gauges in-dicate the system is empty of refrigerant.

Always use precaution when a fitting is removed.Slowly loosen the fitting. If the system is still un-der pressure, release it slowly in a well ventilatedarea.

Personal injury or death can result from inhalingrefrigerant through a lit cigarette.

Inhaling air conditioner refrigerant gas through alit cigarette or other smoking method or inhalingfumes released from a flame contacting air con-ditioner refrigerant gas, can cause bodily harm ordeath.

Do not smoke when servicing air conditioners orwherever refrigerant gas may be present.

Use a certified recovery and recycling cart to prop-erly remove the refrigerant from the air condition-ing system.

g02508540Illustration 292Refrigerant dryer

The refrigerant dryer is located inside the enclosedcompartment with the fuel shutoff valve and thesteering charge filter. This compartment is above thefender, forward and below the fuel tank fill cap on theleft-hand side of the machine.


Note: The “R-134a” refrigerant dryer should bereplaced every 2 years. Extremely humid operatingconditions may require more frequent replacement ofthe dryer. The dryer should also be replaced if the airconditioning system has been leaking or if the systemhas been opened for service repair.

Reference: For the correct procedure, refer toAir Conditioning and Heating Service Manual,SENR5664 or the Disassembly and AssemblyManual for your machine.

Note: A qualified mechanic should replace thecomponents of the refrigerant system since specialtooling and training are required.


Ripper Linkage and Cylinder Bearings - Lubricate

i01286780

Ripper Linkage and CylinderBearings - LubricateSMCS Code: 6313-086-BD, L4


Lubricate twelve grease fittings (six per side). UseMPGM Grease.

i00925689

Ripper Tip and Shank Protector- Inspect/ReplaceSMCS Code: 6808-040; 6808-510; 6810; 6812-040;6812-510

If equipped:


When the ripper tip is worn close to the shank,replace the ripper tip. When the shank protector isworn close to the shank, replace the shank protector.If the tip is too blunt, the tip will not penetrate properly.

1. Raise the ripper. Place blocking under the ripper.Lower the ripper onto the blocking. The rippershould be high enough so that the ripper tip or theshank protector can be removed. Do not place theripper too high.

2. If the ripper tip is worn, drive out the pin. Removethe tip and the shank pin retainer.

3. Clean the shank pin retainer and the pin.

4. Install the new tip and the retainer.

5. Install the pin from the opposite side of theretainer.

6. If the shank protector is worn, drive out the pins.Remove the shank protector.

7. Clean the pin retainers and the pins.

8. Install the new shank protector and the retainers.

9. Install the pins from the opposite side of theretainer.

10.Raise the ripper and remove the blocking.

11. Lower the ripper to the ground.

200 SEBU8593-01Maintenance SectionRollover Protective Structure (ROPS) - Inspect

i02016045

Rollover Protective Structure(ROPS) - InspectSMCS Code: 7325-040

g01042319Illustration 296Front view

Inspect both sides of the Rollover Protective Structure(ROPS) for bolts that are loose or damaged. Replaceany damaged bolts and any missing bolts withoriginal replacement parts only. Tighten the ROPSbolts to a torque of 1800 ± 200 N·m (1330 ± 148 lb ft).

Note: Apply oil to all bolt threads for the ROPSbefore you install the ROPS bolts.

Do not weld reinforcement plates to the ROPSin order to straighten the ROPS. Do not weldreinforcement plates to the ROPS in order to repairthe ROPS.

If the ROPS has any cracks in the welds, in thecastings, or in any metal section, consult yourCaterpillar dealer for repairs.

i04423622

Seat Belt - InspectSMCS Code: 7327-040

Always inspect the condition of the seat belt and thecondition of the seat belt mounting hardware beforeyou operate the machine. Replace any parts that aredamaged or worn before you operate the machine.

g02620101Illustration 297Typical example

Inspect buckle (1) for wear or for damage. If thebuckle is worn or damaged, replace the seat belt.

Inspect seat belt (2) for webbing that is worn orfrayed. Replace the seat belt if the webbing is wornor frayed.

Inspect all seat belt mounting hardware for wear orfor damage. Replace any mounting hardware thatis worn or damaged. Make sure that the mountingbolts are tight.

If your machine is equipped with a seat beltextension, also perform this inspection procedure forthe seat belt extension.

Contact your Cat dealer for the replacement of theseat belt and the mounting hardware.

Note: The seat belt should be replaced within 3 yearsof the date of installation. A date of installation labelis attached to the seat belt retractor and buckle. If thedate of installation label is missing, replace belt within3 years from the year of manufacture as indicatedon belt webbing label, buckle housing, or installationtags (non-retractable belts).

i04421974

Seat Belt - ReplaceSMCS Code: 7327-510

The seat belt should be replaced within 3 years ofthe date of installation. A date of installation label isattached to the seat belt retractor and buckle. If thedate of installation label is missing, replace belt within3 years from the year of manufacture as indicatedon belt webbing label, buckle housing, or installationtags (non-retractable belts).


Steering Charge Filter - Replace


Typical Example

(1) Date of installation (retractor)(2) Date of installation (buckle)(3) Year of manufacture (tag) (fully extended Web)(4) Year of manufacture (underside) (buckle)

Consult your Cat dealer for the replacement of theseat belt and the mounting hardware.

Determine age of new seat belt before installing onseat. A manufacture label is on belt webbing andimprinted on belt buckle. Do not exceed install bydate on label.

Complete seat belt system should be installed withnew mounting hardware.

Date of installation labels should be marked andaffixed to the seat belt retractor and buckle.

Note: Date of installation labels should bepermanently marked by punch (retractable belt) orstamp (non-retractable belt).

If your machine is equipped with a seat beltextension, also perform this replacement procedurefor the seat belt extension.

i04346782

Steering Charge Filter -ReplaceSMCS Code: 431F-510




g02501857Illustration 299Hydraulic oil tank located above right-hand fender

(1) Hydraulic tank filler cap(2) Pressure relief check valve(3) Oil level sight gauge

1. Remove any built up pressure in the hydraulictank. Depress check valve (2) on top of the tank.

202 SEBU8593-01Maintenance SectionTorque Converter Scavenge Screen - Clean

g02501916Illustration 300(4) Left-hand cab entry door (reference only)(5) Steering charge filter element

2. Locate steering charge filter element (5). The filteris inside the enclosed compartment forward andbelow the fuel tank fill cap on the left-hand side ofthe machine above the fender.

3. Remove the filter element. Discard the used filterelement properly. Make sure that all of the old filterseal is removed from the filter base.

4. Clean the filter base with a clean cloth.

5. Apply a thin coat of oil to the seal on the new filter.Install the new filter element by hand.

Instructions for the installation of the filter areprinted on the side of each Caterpillar spin-onfilter. For non-Caterpillar filters, refer to theinstallation instructions that are provided by thesupplier of the filter.

i03967449

Torque Converter ScavengeScreen - CleanSMCS Code: 3101-070-MGS; 3105



After a major power train component failure, cleanthe torque converter scavenge screen.

1. Remove the bottom guard in order to gain accessto the torque converter.

Note: Drain all fluids into a suitable container.


2. Remove the bolts and drain valve body (1 ) fromthe torque converter, as shown.

3. Remove torque converter scavenge screen (2)from the torque converter housing.

4. Wash the screen in a clean, nonflammablesolvent.

5. Install torque converter scavenge screen (2) inthe torque converter housing. Install the bolts anddrain valve body (1).

6. Install the bottom guard.

Reference: See Operation and Maintenance Manual,“Power Train System Oil Level - Check” in order tofill with oil.

SEBU8593-01 203Maintenance SectionTrack - Check/Adjust

i04560064

Track - Check/AdjustSMCS Code: 4170-036


Check the track adjustment. Check the track for wearand for excessive dirt buildup.

Grease is under high pressure.

Grease coming out of the relief valve under pres-sure can penetrate the body causing injury ordeath.

Do not watch the relief valve to see if grease is es-caping. Watch the track or track adjustment cylin-der to see if the track is being loosened.

Loosen the relief valve only one turn.

1. Move the machine forward. Allow the machineto coast to a stop without the use of the servicebrakes. Adjust the tracks while you are in typicaloperating conditions for the machine. If packingconditions prevail on the workplace, the tracksshould be adjusted without removing the packedmaterial.

2. To measure the sag in the track, stretch a stringover the grousers that are between the sprocketand the front idler. Take the measurement fromthe string to the top of the grouser at the maximummeasurement. Dimension (A) is the maximumdistance between the string and the grouser.


If a machine does not have carrier rollers, the sag inthe track is measured between the sprocket and thefront idler. The correct adjustment of dimension (A)is 130 ± 10 mm (5.12 ± 0.4 inch).


If the machine is equipped with a carrier roller,calculate the average of dimension (B) and dimension(C). The correct average value is 65 ± 10 mm(2.6 ± 0.4 inch).

Loose Track Adjustment


See the following Notice for maximum dimension (D).

204 SEBU8593-01Maintenance SectionTrack Pins - Inspect

NOTICEDo not attempt to tighten track when the dimensionbetween the front edge of the wear sleeve on the fronttrack roller frame and the edge of the track roller framesupport is 189 mm (7.4 inch) or more. Contact yourCaterpillar dealer for track service or instructions.

1. Remove the access cover.


2. Add multipurpose grease (MPGM) throughtrack adjustment valve (1). Add the MPGM untildimension (A, B, C) is correct.

3. Operate the machine back and forth in order toequalize the pressure. Allow the machine to coastto a complete stop. Do not use the brakes.

4. Remeasure dimension (D).

Tight Track Adjustment1. Loosen relief valve (2) by one turn of 360 degrees.Allow the grease to escape.

2. Close the relief valve.

3. Add MPGM through track adjustment valve (1).Add grease until dimension (A, B, C) is correct.

4. Install the access cover.

Bolt Torque for Track ShoesThe torque requirement for track shoe bolts is870 ± 90 N·m (650 ± 65 lb ft). Tighten the bolts foran additional 120 degrees. If you are using boltswith a master link, tighten the bolts to a torque of870 ± 90 N·m (650 ± 65 lb ft). Then, tighten the boltsfor an additional 120 degrees.

i01967541

Track Pins - InspectSMCS Code: 4175-040-PN

Fingers can be burned from hot pins and bush-ings.

The pins and bushings in a dry joint can becomevery hot. It is possible to burn the fingers if thereis more than brief contact with these components.

Use the recommendations in order to extend the lifeof the undercarriage. Use the recommendations inorder to avoid excessive downtime.


1. During the machine operation, listen for unusualsqueaking and for unusual squealing. This canindicate a dry joint.

2. Check the machine for dry joints weekly. Checkfor dry joints immediately after machine operation.After machine operation, lightly touch the end ofeach track pin or bushing. Touch the track pinor the track bushing with the back of your hand.Make a mark on any dry track pin joint that is veryhot to the touch.

3. Do not hit the ends of the track pins with a sledgehammer in order to loosen the track joints.

NOTICEStriking the end of a track pin introduces a significantamount of end play into the track joint and can resultin early failures.

Consult your Caterpillar dealer's Custom TrackService expert if you detect dry joints or leaks. YourCaterpillar dealer's Custom Track Service expert canperform track inspection.


Track Roller Frame - Inspect

i02039992

Track Roller Frame - InspectSMCS Code: 4151-040


Inspect the track roller frame (3) for leaks. Check theseal for the pivot shaft (2) for oil leaks. Check theidlers (1) and track rollers (4) for leaks. Inspect theseal for the recoil spring (5) for oil leaks.

i01967485

Track Roller Frame Guides -InspectSMCS Code: 4177-040

Measure the rotational movement of the front rollerframe relative to the rear roller frame.


Some components are removed for clarity.

1. Raise the front of the machine with the hydraulicsof the dozer. Place a 100 mm (4 inch) block underthe outside edge of a track grouser. Place theblock near the track idler. Lower the machine ontothe block.


2. Use a grease pencil to make a mark on the tubularsection of the front roller frame. Make a markon the rear of the roller frame. This mark shouldcorrespond with the mark that is on the tubularsection.


Some components are removed for clarity.

3. Raise the front of the machine with the hydraulicsof the dozer. Place the block under the inside edgeof the same track grouser. Lower the machineonto the block.


206 SEBU8593-01Maintenance SectionWalk-Around Inspection

4. Put a mark on the tubular section of the front rollerframe. This mark should correspond with the markon the rear roller frame. Measure the distancebetween the two marks on the front roller frame.

If the distance between the two marks is greaterthan 4.5 mm (.18 inch), inspect the track roller frameguides for wear.

Repeat the entire procedure for the other side of themachine.

NOTICENever build up the track roller frame guides with hard-face welding. This will cause serious wear damage tothe guide slots in the front track roller frame.


If dimension (X) is less than 45.3 mm (1.78 inch),replace the track roller frame guides. Consult yourCaterpillar dealer for information or for service.

i03409088

Walk-Around InspectionSMCS Code: 1000; 7000

Reference: See Operation and Maintenance Manual,“Daily Inspection” for more information.

i02775471

Winch Fairlead Rollers -LubricateSMCS Code: 5163-086

If equipped:


Lubricate the five fittings. Use MPGM Grease.

i02775441

Winch Oil Level - CheckSMCS Code: 5163-535-FLV

If equipped:

PA140VS


1. Remove the oil level plug (2) in order to check theoil level. The oil level should be maintained to thebottom of the level plug hole.

2. If necessary, remove oil filler plug (1) and add oil.

Check for oil leaks around the covers and aroundthe hoses. Repair any oil leaks.


Winch Oil and Breather - Change/Clean

i01369498

Winch Oil and Breather -Change/CleanSMCS Code: 5163-044

If equipped:



PA59HS


1. Remove the oil filler plug.


2. Remove the drain plug on the bottom of the winch.Allow the oil to drain into a suitable container.

3. Inspect the plug seal. If necessary, replace theplug seal.

4. Clean the drain plug and install the drain plug.


5. Remove the oil level plug.

6. Fill the oil compartment until oil is visible at thebottom of the opening for the oil level plug.See Operation and Maintenance Manual, “RefillCapacities”.


7. Clean the vent plug that is in the filler plug. Use aclean nonflammable solvent.

8. Install the oil filler plug.

9. Run the engine at low idle. Maintain the oil levelso that the oil level is visible at the bottom of theopening for the oil level plug.

10. Install the oil level plug.

208 SEBU8593-01Maintenance SectionWinch Wire Rope - Install

i02094238

Winch Wire Rope - Install(If Equipped)SMCS Code: 5154-012; 5163-012

Personal injury or death can result from worn wirerope cable.

Worn or frayed cable could break causing injury.

Check the wire rope cable. If cable is worn or isfrayed install a new cable.

PA140VSThe cable is attached to the drum on the winch witha cable ferrule. The ferrule is placed into a socketon the drum.

Use the following table to order the cable.

Table 30

Wire Cable

Wire RopeDiameter

RecommendedFerrule

Holding Capacity

25 mm (1 inch) L-8 91 m (300 ft)

29 mm(1.13 inch)

J-9 84 m (276 ft)

32 mm(1.25 inch)

J-10 59 m (193 ft)


1. Put the cable in a straight line behind the tractor.

2. Install the ferrule end into the socket.

3. Reel in the cable.

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Window Washer Reservoir -Fill(If Equipped)SMCS Code: 7306-544

NOTICEWhen operating in freezing temperatures, useCaterpillar or any commercially available nonfreezingwindow washer solvent.

g02511337Illustration 321Left-hand battery and window washer fluid reservoir compartment(Left-hand guard rail assembly removed for illustration)

(1) Compartment access cover (in opened position)(2) Window washer fluid reservoir filler cap

Window Washer – The window washerfluid reservoir is located in the compartmentwith the batteries on the left-hand side of

the machine. Access cover (1) is on the left-hand sideof the machine next to the operator compartment.Remove window washer fluid reservoir filler cap (2)in order to fill the window washer fluid reservoir.


Window Wipers - Inspect/Replace

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Window Wipers -Inspect/Replace(If Equipped)SMCS Code: 7305-040; 7305-510


Inspect the front window wiper blade, the right-handdoor window wiper blades, the left-hand door windowwiper blades, and the rear window wiper blade.Replace any wiper blades that are damaged or worn.Replace any wiper blades that streak the windows.

i04066452

Windows - CleanSMCS Code: 7310-070; 7340-070

If equipped:

Use commercially available window cleaningsolutions to clean the windows.

One wiper blade is used to clean the rear window. Inorder to clean the outside of the rear window from theground, use a long pole.


Documents

Maintenance Intervals - Sebu8593-01 m (Tra)