D7G

MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt

© 2010 Caterpillar All Rights Reserved

®

®

SEBU8252-01 August 2007

Operation and Maintenance Manual D7G and D7G Series II Track-Type Tractors 7MB5000-Up (Machine) X7C100-Up (Machine) C7G1000-Up (Machine)

66 Maintenance Section Maintenance Interval Schedule

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Maintenance Interval Schedule

Hydraulic System Oil Level - Check ..................... 94 Seat Belt - Inspect ................................................ 98 Transmission Oil Level - Check .......................... 106

SMCS Code: 7000

Every 50 Service Hours or Weekly

Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed.

Bulldozer Cylinder Support Bearings - Lubricate .. 70 Ripper Linkage and Cylinder Bearings Lubricate ............................................................. 97 Sprocket Hub Bearings - Inspect .......................... 99 Track Pins - Inspect ............................................ 102 Track Roller Frame Bearings - Lubricate ............ 102

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The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components.

Every 100 Service Hours or 2 Weeks Hydraulic Control Linkage - Lubricate ................... 92

Every 250 Service Hours or Monthly

Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, in order to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance.

Belts - Inspect/Adjust/Replace .............................. 69 Bulldozer Tilt Brace - Lubricate ............................. 70 Fan Drive Bearing - Lubricate ............................... 84 Final Drive Oil Level - Check ................................ 85 Track - Check/Adjust ........................................... 100

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

Every 250 Service Hours or 3 Months

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

When Required Battery - Recycle .................................................. 68 Battery, Battery Cable or Battery Disconnect Switch Replace ............................................................... 68 Condenser (Refrigerant) - Clean .......................... 71 Cutting Edges and End Bits - Inspect/Replace ..... 77 Engine Air Filter Primary Element - Clean/ Replace ............................................................... 78 Engine Air Filter Secondary Element - Replace ... 79 Engine Air Precleaner - Clean .............................. 80 Ether Starting Aid Cylinder - Replace ................... 83 Fuel System - Prime ............................................. 86 Fuses and Circuit Breakers - Replace/Reset ........ 90 Oil Filter - Inspect .................................................. 96 Radiator Core - Clean ........................................... 96 Radiator Pressure Cap - Clean/Replace .............. 96 Ripper Tip and Shank Protector - Inspect/ Replace ............................................................... 97 Window Washer Reservoir - Fill .......................... 108 Window Wipers - Inspect/Replace ...................... 109 Windows - Clean ................................................. 109

Every 10 Service Hours or Daily Backup Alarm - Test .............................................. Brakes, Indicators and Gauges - Test ................... Cooling System Coolant Level - Check ................ Engine Oil Level - Check ...................................... Fuel System Primary Filter (Water Separator) Drain ................................................................... Fuel Tank Water and Sediment - Drain ................. Horn - Test ............................................................

Engine Oil and Filter - Change ............................. 81

68 69 74 80 86 89 91

Cooling System Coolant Sample (Level 2) Obtain ................................................................. 76

Every 500 Service Hours Cooling System Coolant Sample (Level 1) Obtain ................................................................. 75 Final Drive Oil Sample - Obtain ............................ 85 Transmission Oil Sample - Obtain ...................... 107

Every 500 Service Hours or 3 Months Engine Crankcase Breather - Clean ..................... 80 Equalizer Bar Pads - Inspect/Replace .................. 83 Fuel System Primary Filter - Clean/Replace ......... 87 Fuel System Secondary Filter - Replace .............. 88 Fuel Tank Cap and Strainer - Clean ..................... 89 Hydraulic System Oil Filter - Replace ................... 93 Hydraulic System Oil Sample - Obtain ................. 94 Sprocket Hub Bearings - Inspect .......................... 99 Transmission Oil Filter - Replace ........................ 106

Every 1000 Service Hours Battery - Inspect .................................................... 68

Every 1000 Service Hours or 6 Months Transmission Magnetic Screen - Clean .............. 103 Transmission Oil - Change ................................. 104

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67 Maintenance Section Maintenance Interval Schedule

Every 2000 Service Hours or 1 Year Engine Valve Lash - Check ................................... Engine Valve Rotators - Inspect ........................... Final Drive Oil - Change ....................................... Hydraulic System Oil - Change ............................. Sprocket Hub Bearings - Adjust ............................

82 82 84 92 99

Every Year Cooling System Coolant Sample (Level 2) Obtain ................................................................. 76

Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt - Replace ............................................... 98

Every 4000 Service Hours or 2 Years Cooling System Water Temperature Regulator Clean/Replace .................................................... 77

Every 6000 Service Hours or 3 Years Cooling System Coolant Extender (ELC) - Add .... 73

Every 12 000 Service Hours or 6 Years Cooling System Coolant (ELC) - Change ............. 71

68 Maintenance Section Backup Alarm - Test

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3. Close the battery access cover.

Backup Alarm - Test i00993589

SMCS Code: 7406-081

Battery - Recycle SMCS Code: 1401-561 Always recycle a battery. Never discard a battery. Always return used batteries to one of the following locations:

• A battery supplier • An authorized battery collection facility • Recycling facility Illustration 82

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In order to test the alarm for proper functioning, turn engine start switch (1) to the ON position. Apply both brakes (2). Disengage parking brake (3). Move transmission control lever (4) to the REVERSE position.

Battery, Battery Cable or Battery Disconnect Switch Replace SMCS Code: 1401-510; 1402-510; 1411-510

The backup alarm should sound immediately. The alarm alerts the personnel behind the machine that the machine is backing up. The backup alarm will continue to sound until transmission control lever (4) is moved to the NEUTRAL position or to the FORWARD position.

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

The backup alarm is at the rear of the machine. The nonadjustable backup alarm is set at the appropriate sound level when the machine is shipped from the factory.

3. Disconnect the battery cable at the battery disconnect switch. The battery disconnect switch is connected to the machine frame.

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2. Turn the battery disconnect switch to the OFF position. Remove the key.

4. Disconnect the negative battery cable at the battery.

Battery - Inspect

5. Make necessary repairs or replace the battery.

SMCS Code: 1401-040

6. Connect the negative battery cable at the battery.

Tighten the battery retainers on all batteries at every 1000 hour interval.

7. Connect the battery cable at the battery disconnect switch.

Perform the following procedures at every 1000 hour interval. Check these areas more often, if necessary.

8. Install the key and turn the battery disconnect switch to the ON position.

1. Open the battery access cover. The battery access cover is located on the left side or right side of the machine next to the operator’s compartment. 2. Clean the top of the batteries with a clean cloth. Keep the terminals clean and coated with petroleum jelly. Install the terminal covers after you coat the terminals.

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69 Maintenance Section Belts - Inspect/Adjust/Replace

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Belts - Inspect/Adjust/Replace SMCS Code: 1357-025; 1357-040; 1357-510

Inspect 1. Open the engine access doors on both sides of the machine, as needed. Note: Even if only one belt is worn or damaged, replace the belts in sets. 2. Inspect the condition of the fan drive belt, the alternator and water pump belt, and the air conditioning compressor belt. The belts should deflect 14 to 20 mm (.56 to .81 inch) under 110 N (25 lb) of force. Use a 144-0235 Belt Tension Gauge in order to measure the tension.

Adjust/Replace

Illustration 84

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Air conditioning compressor belt (A) Front view (B) Rear view

1. Loosen bolts (1). 2. Turn adjusting nut (2) until the correct belt tension is reached. To achieve the correct belt adjustment, move the compressor inward or move the compressor outward, as required. 3. Tighten bolts (1). Tighten adjusting nut (2). 4. Close the access doors. Illustration 83

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Alternator and fan drive

1. Loosen bolts (1). 2. Loosen adjusting nuts (2). To achieve the correct belt adjustment, move the alternator inward or move the alternator outward, as required. Tighten adjusting nuts (2). 3. Tighten bolts (1).

Note: Use the same procedure in order to replace the belts. Note: If new belts are installed, check the belt adjustment again after 30 minutes of engine operation. i02564751

Brakes, Indicators and Gauges - Test SMCS Code: 4100-081; 7450-081 Before you operate the machine, perform the following checks and make any necessary repairs.

70 Maintenance Section Bulldozer Cylinder Support Bearings - Lubricate

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Bulldozer Cylinder Support Bearings - Lubricate (If Equipped) SMCS Code: 6050-086

Illustration 85

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• Check for the following damage: broken lenses

on the gauges, broken indicator lights, broken switches, and other broken components in the cab.

• Start the engine. • Check the monitor panel for proper operation. See Operation and Maintenance Manual, “Monitoring System”.

• Check for oil leaks. Repair any oil leaks around the covers or around the hoses.

Illustration 86

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1. Lubricate the three fittings on the left side of the machine. 2. Lubricate the three fittings on the right side of the machine.

• Look for inoperative gauges. • Turn on all machine lights. Check for proper operation.

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

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Bulldozer Tilt Brace - Lubricate (If Equipped) SMCS Code: 6050-086

brakes. If the service brakes malfunction, consult your Caterpillar dealer for repairs.

• Engage the parking brake. Move the machine

forward in order to test the parking brake. If the parking brake malfunctions, consult your Caterpillar dealer for repairs.

Illustration 87

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71 Maintenance Section Condenser (Refrigerant) - Clean

Lubricate the grease fittings. Lubricate two fittings on each tilt brace, as needed. i02573839

Condenser (Refrigerant) Clean

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Cooling System Coolant (ELC) - Change SMCS Code: 1395-044

SMCS Code: 1805-070 NOTICE If excessively dirty, clean condenser with a brush. To prevent damage or bending of the fins, do not use a stiff brush. Repair the fins if found defective.

For information about adding an extender to your cooling system, see the Topic “Cooling System Coolant Extender (ELC) - Add” in this manual or consult your Caterpillar dealer. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

To Drain the Cooling System The filler cap is located inside the radiator access door on the top of the engine enclosure.

Illustration 88

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1. Remove the cover for the condenser. 2. Inspect the condenser for debris. Clean the condenser, if necessary. 3. Use clean water to wash all of the dust and dirt from the condenser. 4. Install the cover for the condenser.

Illustration 89

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72 Maintenance Section Cooling System Coolant (ELC) - Change

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3. Route the drain hose through the left hole in the radiator guard in order to drain the coolant. Direct the drain hose into a suitable container.

Illustration 90

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Rear view of radiator Illustration 92

Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand. Cooling System Conditioner contains alkali. Avoid contact with skin and eyes. 1. Slowly loosen filler cap (1) in order to relieve system pressure. Remove the filler cap. 2. The drain valve for coolant is located under the left side of the radiator. Open the left engine access door in order to properly access radiator drain valve (2).

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4. Open the drain valve. Allow the coolant to drain into a suitable container. 5. Flush the system with water. Flush the system until the draining water is clear. Note: If the cooling system is already using ELC, cleaning agents are not required to be used at the specified coolant change interval. Cleaning agents are only required if the system has been contaminated by the addition of some other type of coolant or by cooling system damage. Clean water is the only cleaning agent that is required when ELC is drained from the cooling system. Note: If you change to an ELC from another type of coolant, use a Caterpillar cleaning agent to flush the cooling system. After you drain the cooling system, thoroughly flush the cooling system with clean water. All of the cleaning agent must be removed from the cooling system.. 6. Close the radiator drain valve completely. 7. Replace the drain hose inside the radiator guard.

Filling The Cooling System 1. Add the ELC solution. See the following topics in this publication:

• Capacities (Refill)

Illustration 91 Front view of radiator guard

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Note: Caterpillar antifreeze contains additive. If you are using Caterpillar antifreeze, do not add the supplemental coolant additive at this time. Also, do not change the supplemental coolant additive element at this time.

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73 Maintenance Section Cooling System Coolant Extender (ELC) - Add

2. Start the engine. Run the engine without the filler cap until the thermostat opens and the coolant level stabilizes. 3. Maintain the coolant level at 13 mm (0.5 inch) from the bottom of the filler tube. Add coolant to the filler tube, if necessary. 4. If the gasket is damaged, replace the filler cap. Install the filler cap. 5. Stop the engine.

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Cooling System Coolant Extender (ELC) - Add SMCS Code: 1395-538 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Table 6

Illustration 93

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6. Clean the radiator cores with compressed air. You may need to use water in order to remove debris. 7. Close the engine access door. For additional information about the cooling system coolant, see Operation and Maintenance Manual, SEBU6250, “Caterpillar Machine Fluids Recommendations”, “Cat Extended Life Coolant (ELC)” or consult your Caterpillar dealer.

RECOMMENDED AMOUNT OF EXTENDER BY COOLING SYSTEM CAPACITY Cooling System Capacity

Recommended Amount of Extender

22 to 30 L (6 to 8 US gal)

0.57 L (0.60 qt)

30 to 38 L (8 to 10 US gal)

0.71 L (0.75 qt)

38 to 49 L (10 to 13 US gal)

0.95 L (1 qt)

49 to 64 L (13 to 17 US gal)

1.18 L (1.25 qt)

65 to 83 L (17 to 22 US gal)

1.60 L (54 oz)

When a Caterpillar Extended Life Coolant (ELC) is used, an extender must be added to the cooling system. See the Operation and Maintenance Manual, “Maintenance Interval Schedule” for the proper service interval. The amount of extender is determined by the cooling system capacity. For additional information about adding an extender, see Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations” or consult your Caterpillar dealer.

74 Maintenance Section Cooling System Coolant Level - Check

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

Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure.

Illustration 94

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1. The filler cap is located on the top of the engine enclosure. Slowly loosen the filler cap in order to relieve the pressure. Remove the cap. 2. Add the proper amount of ELC Extender. Add ELC (Extended Life Coolant). Drain some coolant from the radiator into a suitable container in order to allow space for the extra ELC. Reference: See “Capacities (Refill)” in this publication for more information on system capacity. Note: Always discard drained fluids according to local regulations. 3. Start the engine. Run the engine without the filler cap until the thermostat opens and the coolant level stabilizes. Check for leaks.

Illustration 95

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1. Open the radiator access cover on top of the engine enclosure. 2. Remove the cooling system pressure cap slowly in order to relieve the pressure.

4. Check the coolant level. If necessary, add premixed coolant in order to correct the coolant level.

3. Maintain the coolant level at 13 mm (0.5 inch) from the bottom of the filler pipe. If it is necessary to add coolant daily, check the system for leaks.

5. Inspect the filler cap gasket. Replace the filler cap if the gasket is damaged.

4. Install the cooling system pressure cap. Close the radiator access cover.

6. Install the filler cap.

5. Inspect the radiator core for debris. Clean the radiator core, if necessary. Reference: See “Radiator Core - Clean” in the Maintenance Section of this publication for more information.

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75 Maintenance Section Cooling System Coolant Sample (Level 1) - Obtain

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Cooling System Coolant Sample (Level 1) - Obtain SMCS Code: 1350-008; 1395-008; 7542 Note: It is not necessary to obtain a Coolant Sample (Level 1) if the cooling system is filled with Cat ELC (Extended Life Coolant). Cooling systems that are filled with Cat ELC should have a Coolant Sample (Level 2) that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule. Note: Obtain a Coolant Sample (Level 1) if the cooling system is filled with any other coolant instead of Cat ELC. This includes the following types of coolants.

• Commercial long life coolants that meet the Caterpillar Engine Coolant Specification -1 (Caterpillar “EC−1”)

• Cat Diesel Engine Antifreeze/Coolant (DEAC) • Commercial heavy-duty antifreeze/coolant NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. Note: Level 1 results may indicate a need for Level 2 Analysis.

2. The cooling system pressure cap (1) is located on the top of the radiator. Remove the cooling system pressure cap slowly in order to relieve system pressure. 3. Obtain the coolant sample from radiator filler pipe (2). Collect the sample into the proper sampling bottle. Note: Always discard drained fluids according to local regulations. Obtain the sample of the coolant as close as possible to the recommended sampling interval. In order to receive the full effect of S·O·S analysis, you must establish a consistent trend of data. In order to establish a pertinent history of data, perform consistent samplings that are evenly spaced. Supplies for collecting samples can be obtained from your Caterpillar dealer. Use the following guidelines for proper sampling of the coolant:

• Complete the information on the label for the sampling bottle before you begin to take the samples.

• Keep the unused sampling bottles stored in plastic bags.

• Obtain coolant samples directly from the coolant sample port. You should not obtain the samples from any other location.

• Keep the lids on empty sampling bottles until you are ready to collect the sample.

• Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination.

• Never collect samples from expansion bottles. • Never collect samples from the drain for a system. 4. Maintain the coolant level at 13 mm (0.5 inch) from the bottom of the filler pipe. 5. Install cooling system pressure cap (1) onto radiator filler pipe (2). Close the radiator access cover on top of the engine enclosure. Submit the sample for Level 1 analysis. Illustration 96

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1. Open the radiator access cover on top of the engine enclosure.

For additional information about coolant analysis, see Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations” or consult your Caterpillar dealer.

76 Maintenance Section Cooling System Coolant Sample (Level 2) - Obtain

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Cooling System Coolant Sample (Level 2) - Obtain SMCS Code: 1350-008; 1395-008; 7542 NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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Note: Always discard drained fluids according to local regulations. Obtain the sample of the coolant as close as possible to the recommended sampling interval. In order to receive the full effect of S·O·S analysis, you must establish a consistent trend of data. In order to establish a pertinent history of data, perform consistent samplings that are evenly spaced. Supplies for collecting samples can be obtained from your Caterpillar dealer. Use the following guidelines for proper sampling of the coolant:

• Complete the information on the label for the sampling bottle before you begin to take the samples.

• Keep the unused sampling bottles stored in plastic bags.

• Obtain coolant samples directly from the coolant sample port. You should not obtain the samples from any other location.

• Keep the lids on empty sampling bottles until you are ready to collect the sample.

• Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination.

• Never collect samples from expansion bottles. • Never collect samples from the drain for a system. 4. Maintain the coolant level at 13 mm (0.5 inch) from the bottom of the filler pipe. 5. Install cooling system pressure cap (1) onto radiator filler pipe (2). Close the radiator access cover on top of the engine enclosure. Submit the sample for Level 2 analysis.

Illustration 97

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1. Open the radiator access cover on top of the engine enclosure. 2. The cooling system pressure cap (1) is located on the top of the radiator. Remove the cooling system pressure cap slowly in order to relieve system pressure. 3. Obtain the coolant sample from radiator filler pipe (2). Collect the sample into the proper sampling bottle.

For additional information about coolant analysis, see Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations” or consult your Caterpillar dealer.

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77 Maintenance Section Cooling System Water Temperature Regulator - Clean/Replace

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Cooling System Water Temperature Regulator Clean/Replace

NOTICE Since Caterpillar engines incorporate a shunt design cooling system, it is mandatory to always operate the engine with a thermostat.

SMCS Code: 1355-070; 1355-510

Depending on load, failure to operate with a thermostat could result in either an overheating or an overcooling condition.

Replace the thermostat on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system. A new thermostat should be installed after the cooling system has been cleaned. Install the thermostat while the cooling system is completely drained or while the cooling system coolant is drained to a level that is below the thermostat housing. NOTICE Failure to replace the engine’s thermostat on a regularly scheduled basis could cause severe engine damage. Note: If you are only installing a new thermostat, drain the cooling system coolant to a level that is below the thermostat housing.

NOTICE If the thermostat is installed incorrectly, it will cause the engine to overheat. 4. Install a new seal in the thermostat housing. Install a new thermostat and a new gasket. Install the thermostat housing on the engine cylinder head. 5. Install the elbow and the hose. Tighten the hose clamp. 6. Close the left engine access door (if equipped). i02574808

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

Illustration 98

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Rear view

1. Open the left engine access door (if equipped). 2. Remove the bolts from the elbow. Remove the elbow and the thermostat housing assembly. 3. Remove the gasket, the thermostat, and the seal from the thermostat housing. Illustration 99

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

78 Maintenance Section Engine Air Filter Primary Element - Clean/Replace

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2. Remove the bolts. Then remove the cutting edge and the end bits. 3. Thoroughly clean all contact surfaces. 4. Inspect the opposite side of the cutting edge. If the opposite side of the cutting edge is not worn, turn the opposite side of the cutting edge outward and install the cutting edge. 5. If both sides of the cutting edge are worn, install a new cutting edge section. 6. Repeat Steps 4 and 5 for the end bits. 7. Install all bolts and tighten the bolts to the specified torque. Reference: For more information, refer to Specifications, SENR3130, “Torque Specifications”.

Illustration 101

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3. Remove the primary filter element from the air cleaner housing.

8. Raise the bulldozer blade and remove the blocking. Lower the bulldozer blade to the ground. 9. After you operate the machine for a few hours, check all bolts for the proper torque. i02577718

Engine Air Filter Primary Element - Clean/Replace SMCS Code: 1051-070; 1051-510-PY; 1054-070-PY; 1054-510-PY 1. Open the left engine access door (if equipped).

Illustration 102

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4. Clean the inside of the air cleaner housing. 5. Inspect the primary element. If the pleats, the gaskets, or the seals are damaged, discard the element. Replace a damaged primary element with a clean primary element. NOTICE Do not clean the filter elements by bumping or tapping them. Do not use filter elements with damaged pleats, gaskets or seals. Engine damage can result.

Illustration 100

2. Remove the air cleaner cover.

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Make sure the cleaned filter elements are completely dry before installing into the filter housing. Water remaining in the elements can cause false indications of contamination in Scheduled Oil Sampling test results. 6. If the primary element is not damaged, clean the primary element. The filter elements can be cleaned by using the following methods:

• Pressure air

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79 Maintenance Section Engine Air Filter Secondary Element - Replace

• Pressure water

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• Detergent washing When you use pressure air, the maximum air pressure is 205 kPa (30 psi). When you use pressure water, the maximum water pressure is 280 kPa (40 psi).

Engine Air Filter Secondary Element - Replace SMCS Code: 1051-510-SE; 1054-510-SE NOTICE Always replace the secondary filter element. Never attempt to reuse it by cleaning. The secondary filter element should be replaced at the time the primary element is serviced for the third time. The secondary filter element should also be replaced if the yellow piston in the filter element indicator enters the red zone after installation of a clean primary element, or if the exhaust smoke is still black.

Illustration 103

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7. When you clean the inside pleats and the outside pleats, direct the air along the pleats or direct the water along the pleats. The element can be washed in a solution that consists of warm water and of nonsudsing household detergent. Fully rinse the pleats. Allow the filter to air dry completely.

NOTICE The filter should be kept in service for no longer than one year. NOTICE Always leave the secondary filter element in place while you clean the air cleaner housing. 1. Open the engine access door, if equipped. 2. Remove the air cleaner housing cover.

8. Inspect the filter elements after you clean the filter elements. Do not use a filter if the pleats, the gaskets or the seals are damaged.

3. Remove the primary filter element. Refer to Operation and Maintenance Manual, “Engine Air Filter Primary Element - Clean/Replace”.

9. Cover the clean filter elements. Store the elements in a clean, dry location.

4. Clean the inside of the air cleaner housing.

A primary element may be cleaned for a maximum of six times. Also replace the primary element if the primary element has been used for one year. 10. Install a clean primary filter element. 11. Clean the cover and install the cover. 12. Close the access door (if equipped). 13. Reset filter element indicator (1) that is located in the cab (if equipped). Start the engine. If the yellow piston in the filter element indicator moves into the red zone, install a new primary filter element. Also if the exhaust smoke is black, install a new primary filter element.

Illustration 104

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5. Remove the secondary filter element. Pull out in order to remove the element.

80 Maintenance Section Engine Air Precleaner - Clean

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6. Install a new secondary filter element. Push the element firmly in order to properly seat the element. Write the date on the element, if the element is replaced. 7. Install the primary filter element and the air cleaner housing cover. 8. Close the engine access door, if equipped. i02575964

Engine Air Precleaner - Clean SMCS Code: 1050-070

Illustration 106

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Right side view

1. Loosen breather outlet hose clamp (2) and remove the hose from the breather cover. 2. Loosen the breather retaining bolt (1) and remove breather (3). 3. Inspect the breather seal. Replace the breather seal if the breather is damaged. 4. Wash the breather in clean, nonflammable solvent. 5. Use pressure air to dry. 6. Install clean breather (3). 7. Tighten breather retaining bolt (2) to a torque of 14 ± 3 N·m (10 ± 2 lb ft). Illustration 105

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8. Install the hose to breather (3) and tighten hose clamp (2).

1. Inspect the cup visually. The cup should be emptied whenever dirt reaches the indicator mark. 2. Loosen the wing nut on the top of the precleaner. Remove the cover and the cup. Empty and clean the cup. Clean the cover.

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Engine Oil Level - Check SMCS Code: 1302-535-FLV; 1326-535-FLV

3. Install the cup and the cover. Finger tighten the wing nut. Do not use a tool. i02575874

Hot oil and components can cause personal injury.

Engine Crankcase Breather Clean

Do not allow hot oil or components to contact skin.

SMCS Code: 1317-070

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

The engine crankcase breather is located on top of the front side of the engine.

1. Open the engine access door on the left side of the machine (if equipped).

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81 Maintenance Section Engine Oil and Filter - Change

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Engine Oil and Filter - Change SMCS Code: 1308; 1318-510

Illustration 108 Illustration 107

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2. Check dipstick (2) while the engine is running at LOW IDLE WITH WARM OIL. The oil should be at operating temperature. Maintain the oil level between the “ADD” mark and the “FULL” mark. This is the only accurate way to check the oil level.

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1. Remove the crankcase drain valve access cover, which is in the crankcase guard.

Check dipstick (2) with the “ENGINE STOPPED AND COLD OIL”. The oil should be cold. Maintain the oil level in the “SAFE STARTING RANGE”. This method should be used as reference only, before the engine is started. Note: When you operate the machine on severe slopes, the oil level in the engine crankcase must be at the “FULL” mark on the “LOW IDLE” side of dipstick (2). 3. Remove oil filler cap (1). If necessary, add oil. 4. Clean the oil filler cap and install the oil filler cap. 5. Close the engine access door (if equipped).

Illustration 109

g01283497

2. Remove the drain plug. Then, open drain valve (1). Allow the oil to drain into a suitable container. 3. Close the drain valve after all of the oil has drained. Install the drain plug. 4. Install the crankcase drain valve access cover. 5. Open the left engine access door (if equipped).

82 Maintenance Section Engine Valve Lash - Check

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i02562935

Engine Valve Lash - Check SMCS Code: 1102-535; 1209-535

To prevent possible injury, do not use the starter motor to turn the flywheel. Hot engine components can cause burns. Allow additional time for the engine to cool before measuring valve clearance.

Electrical shock hazard. The electronic unit injector system uses 90-120 volts. Illustration 110

g01291352

6. Remove the used crankcase oil filter element. Make sure that all of the old filter seal is removed from the filter base. 7. Apply a thin film of clean engine oil to the new filter seal. 8. Install the new oil filter elements by hand. Instructions for the installation of the filters are printed on the side of each Caterpillar spin-on filter. For non-Caterpillar filters, refer to the installation instructions that are provided by the supplier of the filter. 9. Remove the oil filler cap. Fill the crankcase with new oil. See Operation and Maintenance Manual, “Capacities (Refill) ”. Clean the oil filler cap and install the oil filler cap. 10. Always measure the oil level with the dipstick in order to ensure that the correct amount of oil was added. 11. On the dipstick, maintain the oil level between the “ADD” mark and “FULL” mark. 12. Close the left engine access door.

NOTICE Operation of Caterpillar engines with improper valve adjustments will reduce engine efficiency. This reduced efficiency could result in excessive fuel usage and/or shortened engine component life. NOTICE Measure the valve clearance with the engine stopped. To obtain an accurate measurement, allow at least 20 minutes for the valves to cool to engine cylinder head and engine block temperature. Check the valve bridge before setting the valve lash. Ensure that the valve bridge is seated equally on both valve stems. Refer to your machine’s Service Manual or your Caterpillar dealer for the complete valve adjustment procedure. i02562938

Engine Valve Rotators - Inspect SMCS Code: 1109-040 Perform the following procedure after you set all the valve clearances and before you install the valve cover. 1. Start the engine. 2. Position the governor control lever to the LOW IDLE position.

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Illustration 111

83 Maintenance Section Equalizer Bar Pads - Inspect/Replace

g00679445

3. Watch the top surface on each valve rotator. The rotator should turn slightly. If a valve fails to rotate, consult your Caterpillar dealer.

Illustration 113

g01282952

2. Inspect the rubber pads. Replace the rubber pads if the rubber pad is cracked. Replace the rubber pads if the rubber pad is starting to peel. Install the guards. Consult your Caterpillar dealer for replacements.

i02575870

Equalizer Bar Pads Inspect/Replace

i02575747

Ether Starting Aid Cylinder Replace (If Equipped)

SMCS Code: 7206-040-JP; 7206-510-JP

SMCS Code: 1456-510-CD The ether starting aid cylinder is located on the left side of the engine.

Illustration 112

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1. Remove the guards.

Illustration 114

1. Open the left engine access door.

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84 Maintenance Section Fan Drive Bearing - Lubricate

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Open the right engine access door.

Illustration 115

g01290655

2. Loosen the cylinder retaining clamp from the support that is bolted to the cylinder block casting. Unscrew and remove empty ether starting aid cylinder (not shown). 3. Remove the used gasket. Install the new gasket that is provided with each new ether starting aid cylinder. 4. Install the new ether starting aid cylinder. Tighten the ether starting aid cylinder by hand. Tighten the cylinder retaining clamps securely.

Illustration 117

g00677343

Lubricate the fitting. Close the right engine access door. i02562747

Final Drive Oil - Change SMCS Code: 4050-535-FLV

5. Close the left engine access door. i02575744

Fan Drive Bearing - Lubricate SMCS Code: 1359-086-BD The fitting is located on the right side of the engine.

Illustration 118 Rear view Some components are removed for clarity.

1. Remove the oil filler plug.

Illustration 116

g01290577

g01280809

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85 Maintenance Section Final Drive Oil Level - Check

i02558810

Final Drive Oil Sample - Obtain SMCS Code: 4050-008

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.

Illustration 119

g00679408

2. Remove the drain plug. Drain the oil in a suitable container. 3. Install the drain plug. 4. Maintain the oil level to the bottom of the plug. 5. Clean the filler plug. Install the filler plug. 6. Repeat the procedure for the other final drive.

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

i02558808

Final Drive Oil Level - Check

Obtain the Sample and the Analysis

SMCS Code: 4050-535-FLV

In addition to a good preventive maintenance program, Caterpillar recommends using S·O·S oil analysis at regular scheduled intervals in order to monitor the condition and the maintenance requirements of the final drives. Each oil sample should be taken when the oil is warm and when the oil is well mixed in order to ensure that the sample is representative of the oil in the final drives.

Obtain the S·O·S Sample

Illustration 120

g01280809

Rear view Some components are removed for clarity.

1. Remove the oil filler plug on the inside of the case and frame. 2. Check the oil level. Oil should be to the bottom of the filler plug opening. If necessary, add oil to the final drive. 3. Install the filler plug. Repeat this procedure for the other final drive.

To avoid contamination of the oil samples, the tools and the supplies that are used for obtaining oil samples must be clean.

86 Maintenance Section Fuel System - Prime

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1. Turn the priming pump plunger to the left. This will unlock the priming pump. 2. Operate the pump until a slight pressure is felt. 3. Turn the priming pump plunger to the right. This will lock the priming pump. 4. Start the engine. Inspect the fuel priming pump for leaks. i02575683

Illustration 121

g01280809

Fuel System Primary Filter (Water Separator) - Drain

Rear view of the case and frame

SMCS Code: 1263-543

Oil sampling

1. Remove the oil filler plug and obtain the oil sample with a proper suction device. Use a 1U-7683 Suction Gun or use an equivalent pump such as 1U-5718 Vacuum Pump to take the oil sample. 2. Install the oil filler plug. 3. Repeat Step 1 to Step 2 in order to sample the oil in the other final drive. Refer to Special Publication, PEHP6001 for more information on obtaining a good oil sample. Consult your Caterpillar dealer for complete information and assistance in establishing an S·O·S program for your machine. i02575650

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

SMCS Code: 1258

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.

The priming pump is located inside the right engine access door.

Dispose of all fluids according to local regulations and mandates.

Fuel System - Prime

Illustration 122

g01290529

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87 Maintenance Section Fuel System Primary Filter - Clean/Replace

i02575684

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

Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

Illustration 123

g01290577

1. Open the engine access door on the right side of the machine.

Personal injury or death can result from engine overspeed. If the engine overspeeds, it can cause injury or parts damage. Be prepared to stop the engine by closing the air off to the air inlets or by manually pushing downward on the governor shutdown rod.

Personal injury or death can result from a fire. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Illustration 124

g01290578

2. Extend drain hose (2) into a suitable container. Drain (1) is located under the primary fuel filter/water separator. 3. Open drain (1). Allow the fluid to drain into the container. 4. After the separator is completely drained, close drain (1) by hand pressure only. Dispose of the drained fluid in a safe place.

Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system. Turn the disconnect switch OFF or disconnect the battery when changing fuel filters. NOTICE Do not fill fuel filter with fuel before installing the fuel filter. Contaminated fuel causes accelerated wear to fuel system parts.

88 Maintenance Section Fuel System Secondary Filter - Replace

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3. Remove water collection bowl (1). Unscrew the bowl from element (2). 4. Loosen element (2) from base (3). Remove the element. 5. Install new element (2) onto mounting base (3). 6. Clean the water collection bowl. Install bowl (1) on new element (2). Note: The water collection bowl is reusable. When you can no longer see the contents of the water collection bowl, replace the water collection bowl. 7. Open the fuel shutoff valve at the rear of the machine. 8. Prime the fuel system.

Illustration 125

g01289306

9. Prime the fuel system. See the Operation and Maintenance Manual, “Fuel System - Prime”. i02575726

Fuel System Secondary Filter Replace SMCS Code: 1261-510-SE The secondary fuel filter is located on the right front side of the engine.

Illustration 126

g01290579

1. Open the engine access door on the right side of the machine. 2. Locate the fuel shutoff valve under the fuel tank at the rear of the machine. Turn the handle of the fuel shutoff valve counterclockwise in order to shut off the fuel supply. Illustration 128

g01290608

1. Remove the filter and properly discard the filter. 2. Clean the filter mounting base. Remove all of the old seal. Coat the seal of the new filter with clean diesel fuel. 3. Install the new filter by hand. When the seal contacts the base, tighten 3/4 turn more. 4. Open the fuel supply valve. Illustration 127

g01290580

5. Prime the fuel system.

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89 Maintenance Section Fuel Tank Cap and Strainer - Clean

i02573812

Fuel Tank Cap and Strainer Clean SMCS Code: 1273-070-STR; 1273-070-Z2; 1273-070

Illustration 131

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6. Remove the strainer. 7. Wash the strainer in clean, nonflammable solvent. 8. Install the strainer. Illustration 129

g01289351

9. Install the fuel cap. Install the lock, if necessary.

Left side view

1. Remove the lock, if necessary. To remove fuel cap (1), lift up on the lever. Turn the lever to the left until the lever stops. Remove the cap.

i02573763

Fuel Tank Water and Sediment - Drain SMCS Code: 1273-543-M&S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Illustration 130

g01289343

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.

2. Rotate the fuel cap clockwise until three tabs (6) drop in slots in the adapter. Rotate the lever (4) clockwise until the lever stops. Lower lever (4) over locking tab (5).

Dispose of all fluids according to local regulations and mandates.

3. Replace the filter in the fuel cap.

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

4. To replace the filter, remove two screws that secure filter (3) to the fuel cap. Remove filter (3), valve (2), and the gaskets. 5. Install new components in the reverse order.

90 Maintenance Section Fuses and Circuit Breakers - Replace/Reset

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i02574929

Fuses and Circuit Breakers Replace/Reset SMCS Code: 1417-510; 1420-529; 1420 Fuses – Fuses protect the electrical system from damage that is caused by overloaded electrical circuits. Replace a fuse if the element separates. If the fuse of a particular electrical system requires frequent replacement, check the electrical circuit. Repair the electrical circuit, if necessary. NOTICE Always replace fuses with the same type and capacity fuse that was removed. Otherwise, electrical damage could result. Illustration 132

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1. Open the access cover on the rear of the machine.

NOTICE If it is necessary to replace fuses frequently, an electrical problem may exist. Contact your Caterpillar dealer.

Illustration 133

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2. Open the drain valve and allow the moisture and sediment to drain. 3. Close the drain valve. 4. Close the access cover. Illustration 134

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Open the access door on the left side of the machine to the circuit breakers and the fuses.

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91 Maintenance Section Horn - Test

Wipers (10) – 20 Amp Gauge (11) – 5 Amp Fault Alarm (12) – 5 Amp Blower (13) – 20 Amp

Circuit Breaker

Illustration 135

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Fuses are located behind the cover (not shown).

Fuses

Illustration 137

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Circuit Breaker/Reset – The 80 Amp main circuit breaker is the only circuit breaker. Push in the button in order to reset the circuit breaker. If the electrical system is working properly, the button will remain depressed. Note: If the button does not remain depressed, check the appropriate electrical circuit. Repair the electrical circuit, if necessary. i02054663

Horn - Test Illustration 136 Fuse panel block

Ignition Key (1) – 10 Amp Flood Lights (Front) (2) – 15 Amp Refrigerant Condenser (3) – 15 Amp Operator Monitor (4) – 5 Amp Forward Horn (5) – 10 Amp Flood Lights (Rear) (6) – 10 Amp Refrigerant Condenser (7) – 15 Amp Gauge (8) – 10 Amp Dome Light (9) – 15 Amp

g01290001

SMCS Code: 7402-081 Test the horn on a daily basis. Press downward on the horn button in order to sound the horn. If the horn does not sound, make the necessary repairs before you operate the machine.

92 Maintenance Section Hydraulic Control Linkage - Lubricate

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i02575412

Hydraulic Control Linkage Lubricate (If Equipped) SMCS Code: 5063-086

Illustration 139

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1. To relieve the tank pressure, slowly remove hydraulic oil filler cap (1).

Illustration 138

g01290342

The hydraulic control linkage is located on the right side of the machine. Lubricate two fittings. i02575638

Hydraulic System Oil - Change g01290524

SMCS Code: 5050-044

Illustration 140

The hydraulic oil filter is located behind the right side access door.

2. Open the oil drain valve under the hydraulic oil tank and drain in a suitable container.

The hydraulic oil tank is located on the right side of the rear of the machine.

3. Close the valve.

Illustration 141

g01290365

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Illustration 142

93 Maintenance Section Hydraulic System Oil Filter - Replace

g01290502

4. Open the right side access door. Change hydraulic oil filter (3). Refer to Operation and Maintenance Manual, “Hydraulic System Oil Filter - Replace”. 5. See Operation and Maintenance Manual, “Capacities (Refill)” in order to determine the amount of hydraulic oil that is needed to fill the hydraulic oil tank. Fill the hydraulic oil tank.

Illustration 143

g01290496

Illustration 144

g01290365

6. Inspect the filler cap gasket. Replace the gasket if the gasket is worn or damaged. 7. Install the oil filler cap. 8. Start the engine. Run the engine for a few minutes. 9. Stop the engine. 10. Maintain the oil level to the FULL mark (2) in the sight gauge. See Illustration 142. Add oil, if necessary. 11. Close the right side access door.

1. To relieve the tank pressure, slowly remove hydraulic oil filler cap (1). i02575598

Hydraulic System Oil Filter Replace SMCS Code: 5068-510 The hydraulic oil tank is located on the left side of the rear of the machine. The hydraulic oil filter is located behind the right side access door.

Illustration 145

g01290502

2. Open the right side access door. Remove the hydraulic oil filter element and filter housing(3).

94 Maintenance Section Hydraulic System Oil Level - Check

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3. Remove the used filter element from the housing. Properly discard the filter element. 4. Clean the inside of filter housing (3) with a clean cloth. 5. Install the new hydraulic oil filter element. 6. Clean hydraulic oil filler cap (1) in a clean nonflammable solvent. Install the cap. 7. Maintain oil level to the FULL mark (2) in the sight gauge. 8. Close the right side access door.

Illustration 147

9. Start and run the engine at LOW IDLE for a few minutes. 10. Stop the engine.

g01290365

1. Maintain the oil level to the FULL mark (2) on the sight gauge. 2. Remove hydraulic oil filler cap (1) and add the oil, if necessary.

i02575427

Hydraulic System Oil Level Check

3. Clean the hydraulic oil filler cap. Install the cap.

SMCS Code: 5056-535-FLV; 7479

Hydraulic System Oil Sample - Obtain

i02575523

SMCS Code: 5095-008

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Illustration 146

g01290349

The hydraulic oil tank is located on the right side of the rear of the machine.

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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95 Maintenance Section Hydraulic System Oil Sample - Obtain

Obtain the Sample and the Analysis In addition to a good preventive maintenance program, Caterpillar recommends using S·O·S oil analysis at regular scheduled intervals in order to monitor the condition of the hydraulic system and the maintenance requirements of the hydraulic system. Each oil sample should be taken when the oil is warm and when the oil is well mixed in order to ensure that the sample is representative of the oil in the hydraulic system.

Obtain the S·O·S Sample

At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure. NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. Obtain a sample of the hydraulic oil from the hydraulic tank. The hydraulic tank is located on the right side of the rear of the machine.

Illustration 148

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1. Remove hydraulic tank filler cap (1) slowly in order to relieve any pressure. 2. Remove the filler strainer (not shown). Use a 1U-5718 Vacuum Pump or an equivalent pump. Insert the suction tube into the filler tube and draw a sample of the hydraulic system oil. 3. Replace the filler strainer and the hydraulic tank filler cap. The recommended interval for oil samples is every 500 hours. The recommended hydraulic oil change interval is 2000 hours. Reference: Refer to “Lubricant Viscosities” in the Maintenance Section of this publication for the correct fluid for your machine. Reference: Refer to the Operation and Maintenance Manual, “S·O·S Oil Analysis”. Reference: Refer to Special Publication, PEHP6001 for more information on obtaining a good oil sample. Consult your Caterpillar dealer for complete information and assistance in establishing an S·O·S program for your machine.

96 Maintenance Section Oil Filter - Inspect

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i02106227

i00057294

Oil Filter - Inspect

Radiator Core - Clean

SMCS Code: 1318-507; 3067-507; 5068-507

SMCS Code: 1353-070; 1805; 1810

Inspect a Used Filter for Debris

Illustration 150 Illustration 149

g00100013

The element is shown with debris.

Use a filter cutter to cut the filter element open. Spread apart the pleats and inspect the element for metal and for other debris. An excessive amount of debris in the filter element can indicate a possible failure. If metals are found in the filter element, a magnet can be used to differentiate between ferrous metals and nonferrous metals. Ferrous metals can indicate wear on steel parts and on cast iron parts. Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings, rod bearings, or turbocharger bearings. Small amounts of debris may be found in the filter element. This could be caused by friction and by normal wear. Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found. Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings, to the crankshaft, and to other parts. This can result in larger particles in unfiltered oil. The particles could enter the lubricating system and the particles could cause damage.

g00100062

You can use compressed air, high pressure water, or steam to remove dust and other debris from the radiator core. However, the use of compressed air is preferred. See Special Publication, SEBD0518, “Know Your Cooling System” for the complete procedure for cleaning the radiator core. i02575152

Radiator Pressure Cap Clean/Replace SMCS Code: 1353-070-Z2; 1353-510-Z2

Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure.

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97 Maintenance Section Ripper Linkage and Cylinder Bearings - Lubricate

i02575177

Ripper Tip and Shank Protector - Inspect/Replace SMCS Code: 6808-040; 6808-510; 6810; 6812-040; 6812-510 If equipped:

Tips

Illustration 151

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1. Open the access cover to the radiator cap on top of the engine enclosure. Slowly remove the radiator cap in order to relieve system pressure. 2. Inspect the radiator cap for damage, for deposits, or for foreign material. Clean the radiator cap with a clean cloth. Replace the radiator cap if the radiator cap is damaged. 3. Install the radiator cap. i02578621

Ripper Linkage and Cylinder Bearings - Lubricate SMCS Code: 6313-086-BD, L4

Illustration 153

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When the ripper tip is worn close to the shank, replace the ripper tip. If the tip is too blunt, the tip will not penetrate properly. 1. Raise the ripper. Place blocking under the ripper. Lower the ripper onto the blocking. The ripper should be high enough so that the ripper tip can be removed. Do not place the ripper too high. 2. If the ripper tip is worn, drive out pin (1). Remove tip (2) and the shank pin retainer. 3. Clean the shank pin retainer and the pin. 4. Install the new tip and the retainer. 5. Install pin (1) from the opposite side of the retainer. 6. Raise the ripper and remove the blocking. 7. Lower the ripper to the ground.

Illustration 152

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D7G ripper

1. Lubricate the twenty grease fittings for the ripper arrangement.

98 Maintenance Section Seat Belt - Inspect

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Shank

Illustration 154

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When the ripper shank is worn or damaged, replace the ripper shank. 1. Raise the ripper. Place blocking under the ripper. Lower the ripper onto the blocking. The ripper should be high enough so that the ripper shank can be removed. Do not place the ripper too high. 2. If the shank is worn or damaged, remove cotter pin (3). Then drive out pin (4). Remove shank (5). 3. Install the new shank and pin (4).

Illustration 155

g00932801

Typical example

Check the seat belt mounting hardware (1) for wear or for damage. Replace any mounting hardware that is worn or damaged. Make sure that the mounting bolts are tight. Check buckle (2) for wear or for damage. If the buckle is worn or damaged, replace the seat belt. Inspect the seat belt (3) for webbing that is worn or frayed. Replace the seat belt if the seat belt is worn or frayed. Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware.

4. Install cotter pin (3). 5. Raise the ripper and remove the blocking. 6. Lower the ripper to the ground. i02429589

Seat Belt - Inspect SMCS Code: 7327-040; 7520 Always check the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine. Replace any parts that are damaged or worn before you operate the machine.

Note: Within three years of the date of installation or within five years of the date of manufacture, replace the seat belt. Replace the seat belt at the date which occurs first. A date label for determining the age of the seat belt is attached to the seat belt, the seat belt buckle, and the seat belt retractor. If your machine is equipped with a seat belt extension, also perform this inspection procedure for the seat belt extension. i02429594

Seat Belt - Replace SMCS Code: 7327-510 Within three years of the date of installation or within five years of the date of manufacture, replace the seat belt . Replace the seat belt at the date which occurs first. A date label for determining the age of the seat belt is attached to the seat belt, the seat belt buckle, and the seat belt retractor.

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99 Maintenance Section Sprocket Hub Bearings - Adjust

i02560021

Sprocket Hub Bearings Inspect SMCS Code: 4054-040

Illustration 156 (1) (2) (3) (4)

g01152685

Date of installation (retractor) Date of installation (buckle) Date of manufacture (tag) (fully extended web) Date of manufacture (underside) (buckle)

Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware. If your machine is equipped with a seat belt extension, also perform this replacement procedure for the seat belt extension. i02559987

Sprocket Hub Bearings Adjust

Illustration 158

g01281496

Inspect the sprocket hub bearing on new machines. Inspect the sprocket hub bearing on reconditioned machines. See Operation and Maintenance Manual, “Sprocket Hub Bearings - Adjust”. i02560028

SMCS Code: 4054-025

Sprocket Hub Bearings Inspect SMCS Code: 4054-040

Illustration 157

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Adjust the preload on the sprocket hub bearings. Refer to the Service Manual or consult your Caterpillar dealer.

Illustration 159

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Check for oil leaks on both sides of the sprocket. If the leakage is noticeable, the seals and/or bearings need to be replaced. Refer to the Service Manualfor this procedure. If the Service Manual is not available, contact your Caterpillar dealer.

100 Maintenance Section Track - Check/Adjust

SEBU8252-01

Check the bearing preload. The machine must be put on stands. With the machine off the ground, this will reduce the load on the sprockets. Refer to the Service Manual For this procedure. If the Service Manual is not available, contact your Caterpillar dealer. i02577880

Track - Check/Adjust

NOTICE Do not attempt to tighten the track when dimension (X) is less than 3 mm (0.12 inch). Consult your Caterpillar dealer for track service or instructions. 2. Measure the “X” dimension. 3. Stand on the track between the front idler and the track carrier roller in order to produce as much track sag as possible.

SMCS Code: 4170-036

Grease is under high pressure. Grease coming out of the relief valve under pressure can penetrate the body causing injury or death. Do not watch the relief valve to see if grease is escaping. Watch the track or track adjustment cylinder to see if the track is being loosened. Loosen the relief valve only one turn.

Check Check the track adjustment. Check the track for wear and for excessive dirt buildup. 1. Move the machine forward for a distance of two times the length of the machine. Stop the machine on a level surface without the use of the service brake. Lower all the implements. Apply slight down pressure to all the implements. Engage the parking brake lock lever. Place the transmission in NEUTRAL and stop the engine.

Illustration 161

g01291428

Points (1, 2) are above the centerlines when the machine is stopped.

4. Attach one end of a string to the grouser tip on the track shoe that is directly above track carrier roller (1). Make the string tight by pulling on the string. Attach the opposite end of the string to the grouser tip on the track shoe (2) that is directly above the front idler . 5. Measure the distance between the string and the tip of the grouser that is on the track shoe directly between the front idler and the track carrier roller in order to obtain dimension (A). 6. Dimension (A) should be approximately 50 mm (2.0 inch). If dimension (A) is not correct, adjust the track.

Illustration 160 Left track roller frame

g01281833

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101 Maintenance Section Track - Check/Adjust

Adjust

Grease is under high pressure. Grease coming out of the relief valve under pressure can penetrate the body causing injury or death. Do not watch the relief valve to see if grease is escaping. Watch the track or track adjustment cylinder to see if the track is being loosened. Loosen the relief valve only one turn.

Illustration 163

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(B) Mark on roller frame

1. Move the machine forward for a distance of two times the length of the machine. Allow the machine to a stop without the use of the service brakes. Shut off the engine. Adjust the tracks while you are in the machine’s typical operating conditions. If packing conditions prevail on the job, the tracks should be adjusted with packing material.

4. Mark the roller frame with a pencil or with a marking pen. Make a mark (B) that is 12 mm (0.50 inch) behind idler bearing support (5). This allows the necessary space for the front idler to retract. 5. Allow the idler to move back by opening relief valve (3) ONE TURN ONLY. Move the machine in REVERSE. This will help move the idler backward. 6. Close relief valve (3). 7. Add grease (MPGM) through adjusting valve (4) until the mark on roller frame (B) is aligned with the rear edge of idler bearing support (5). 8. Install the valve cover plate. Tighten the bolts to a torque of 75 ± 15 N·m (55.5 ± 11.0 lb ft).

Illustration 162

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Note: The track sag after this adjustment procedure should be 50 mm (2.0 inch). If track sag is not 50 mm (2.0 inch), repeat the procedure.

2. Remove the cover for the track adjusting mechanism.

9. Repeat the procedure on adjusting of the other track for the other side.

3. Add grease (MPGM) through adjusting valve (4) in order to move the idler forward until the track is fully tight.

Bolt Torque for Track Shoes

Illustration 164

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102 Maintenance Section Track Pins - Inspect

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The torque requirement for track shoe bolts is 300 ± 50 N·m (220 ± 40 lb ft). Tighten the bolts for an additional 120 degrees. If you are using bolts with a master link, tighten the bolts to a torque of 300 ± 50 N·m (220 ± 40 lb ft). Then, tighten the master bolts for an additional 180 degrees. i02560685

Track Pins - Inspect

NOTICE Striking the end of a track pin introduces a significant amount of end play into the track joint and can result in early failures. Consult your Caterpillar dealer’s Custom Track Service expert if you detect dry joints or leaks. Your Caterpillar dealer’s Custom Track Service expert can perform track inspection.

SMCS Code: 4175-040-PN i02579170

Track Roller Frame Bearings Lubricate SMCS Code: 4151-086

Illustration 165

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Fingers can be burned from hot pins and bushings. Illustration 166

The pins and bushings in a dry joint can become very hot. It is possible to burn the fingers if there is more than brief contact with these components.

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Rear of track roller frames

1. Lubricate the two inner bearings. The bearings are located on each roller frame.

Use the recommendations in order to extend the life of the undercarriage. Use the recommendations in order to avoid excessive downtime. 1. During the machine operation, listen for unusual squeaking and for unusual squealing. This can indicate a dry joint. 2. Check the machine for dry joints weekly. Immediately after machine operation ,check for any dry joints. After machine operation, lightly touch the end of each track pin or bushing. Touch the track pin or the track bushing with the back of your hand. Make a mark on any dry track pin joint that is very hot to the touch.

Illustration 167

3. Do not hit the ends of the track pins with a sledge hammer in order to loosen the track joints.

2. Lubricate the two outer bearings. The bearings are located on each side of the machine.

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103 Maintenance Section Transmission Magnetic Screen - Clean

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Transmission Magnetic Screen - Clean

9. Start the engine. Run the engine at LOW IDLE in NEUTRAL.

SMCS Code: 3030-070-MGS 1. Remove the floorplate.

Illustration 168

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Illustration 170

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Illustration 171

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Illustration 172

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Right view

Illustration 169

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(1) Cover (2) Screen (3) Magnet assembly

2. Remove cover (1). 3. Remove screen (2) and magnet assembly (3). 4. Wash the screen and the magnets in clean, nonflammable solvent. Clean the magnets with a cloth, stiff bristle brush or pressure air. 5. Install the magnets. 6. Install the screen. 7. Inspect the spring and the seal. If the seal is damaged, install a new seal. 8. Install the cover and the floorplate.

(A) Cold engine (B) Warm engine

10. Open the door. Maintain the oil between the ADD mark and the FULL mark on transmission oil dipstick (4).

104 Maintenance Section Transmission Oil - Change

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11. Remove transmission oil filler cap (5). If necessary, add the oil. 12. Install the oil filler cap and close the door. i02578230

Transmission Oil - Change SMCS Code: 3030; 3080-044

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Operate the engine in order to warm the oil. Park the machine on level ground. Lower all attachments to the ground. Apply slight downward pressure. Engage the parking brake switch. Stop the engine.

Drain Oil

Illustration 174

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2. Remove the access cover in the bottom guard assembly. Remove the oil drain plug from the torque converter housing. 3. Allow the oil to drain in a suitable container. 4. Clean the drain plugs. Install the drain plugs.

Illustration 173

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Rear view

1. Remove the transmission oil drain plug from the bevel gear case. Drain the oil into a suitable container.

Illustration 175

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5. Remove cover (1) and screen (2) from the torque converter housing. 6. Clean the cover and the screen in nonflammable solvent. 7. Install the cover and the screen. 8. Change the filter element. See Operation and Maintenance Manual, “Transmission Oil Filter Replace”.

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105 Maintenance Section Transmission Oil - Change

9. Clean the transmission magnetic screen. See Operation and Maintenance Manual, “Transmission Magnetic Screen - Clean”.

Fill Oil

Illustration 178

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3. Add oil. Maintain the oil level to the “FULL” mark on the dipstick. Note: To determine the correct amount of oil, see Operation and Maintenance Manual, “Capacities (Refill)”.

Illustration 176

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1. Open the access door for the transmission oil filler cap. The access door is on the right side of the machine.

Illustration 179

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Front view

4. Unscrew the transmission breather and remove the transmission breather. 5. Wash the transmission breather in a clean nonflammable solvent. Illustration 177

2. Remove the transmission oil filler cap.

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6. Install the transmission breather. 7. Start the engine. Run the engine at LOW IDLE. 8. On the dipstick, maintain the oil level between the “ADD” mark and “FULL” mark. 9. Close the access door and stop the engine.

106 Maintenance Section Transmission Oil Filter - Replace

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i02578003

Transmission Oil Filter Replace

2. Remove housing drain plug (2) and allow the oil to drain in a suitable container. 3. Remove housing cover (1).

SMCS Code: 3067-510 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Illustration 182

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4. Remove the used filter element from the housing. 5. Clean the inside of the housing with a clean cloth.

1. Open the left engine access door.

6. Clean the cover. Replace the damaged seal with a new seal. 7. Install the new filter element. 8. Install the housing cover. 9. Clean the drain plug and install the drain plug. i02578130

Transmission Oil Level - Check SMCS Code: 3030-535-FLV; 3080-535-FLV Illustration 180

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Right view

Illustration 181 Section view of transmission oil filter

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The transmission oil dipstick is located on the right side of the machine.

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107 Maintenance Section Transmission Oil Sample - Obtain

2. Measure the oil level with the engine at LOW IDLE. The oil should be at operating temperature. Maintain the oil level to the FULL mark on transmission oil dipstick (1). 3. Remove transmission oil filler cap (2). 4. Add oil, if necessary. Maintain the oil to the FULL mark on transmission oil dipstick (1). 5. Clean transmission oil filler cap (2). Install the cap. 6. Close the access door. i02578159

Transmission Oil Sample Obtain SMCS Code: 3080-008 Illustration 183

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1. Open the right side access door. Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.

Obtain the Sample and the Analysis

Illustration 184

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Obtain the sample of the transmission oil as close as possible to the recommended sampling interval. The recommended sampling interval is every 500 service hours. In order to receive the full effect of S·O·S oil analysis, you must establish a consistent trend of data. In order to establish a pertinent history of data, perform consistent oil samplings that are evenly spaced. If the machine is operated under high load and/or under high temperature conditions, sample all fluids at the 250 hour interval. Each oil sample should be taken when the oil is warm and the oil is well mixed in order to ensure that the sample is representative of the oil in the transmission.

Illustration 185 (A) Cold engine (B) Warm engine

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NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers.

108 Maintenance Section Window Washer Reservoir - Fill

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i02578169

Window Washer Reservoir Fill (If Equipped) SMCS Code: 7306-544 NOTICE When operating in freezing temperatures, use Caterpillar or any commercially available nonfreezing window washer solvent.

Illustration 186

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1. Open the access door on the right side of the machine.

Illustration 188

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Window Washer – The washer fluid bottle is located on the rear of the machine above the fuel tank. Remove the fluid bottle cap in order to fill the washer fluid bottle.

Illustration 187

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2. Remove the transmission oil filler cap. Use a 1U-5718 Vacuum Pump or an equivalent pump. Insert the suction tube in the filler tube and draw an oil sample. 3. Replace the transmission oil filler cap on the filler tube. 4. Close the access door on the right side of the machine. Reference: Refer to , “Lubricant Viscosities” in the Maintenance Section of this manual for the correct fluid for your machine. Reference: Refer to Special Publication, PEHP6001 for more information on obtaining a good oil sample. Consult your Caterpillar dealer for complete information and assistance in establishing an S·O·S program for your machine.

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109 Maintenance Section Window Wipers - Inspect/Replace

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Window Wipers Inspect/Replace (If Equipped) SMCS Code: 7305-040; 7305-510

Illustration 190

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Clean all the cab windows and the door windows.

Illustration 189

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Inspect the front windshield wiper blade and the rear windshield wiper blade. Replace any wiper blades that are damaged or worn. Replace any wiper blades that streak the windshield. i02578689

Windows - Clean SMCS Code: 7310-070; 7340-070 Use commercially available window cleaning solutions to clean the windows.