MAINTENANCE INTERVALS

Operation and Maintenance

Manual Excerpt

® ®
© 2010 Caterpillar
All Rights Reserved
 SEBU7764-10
September 2010

Operation and
Maintenance
Manual
D10T Track-Type Tractor
RJG1-Up (D10T)

SAFETY.CAT.COM
126 SEBU7764-10
Maintenance Section
Maintenance Interval Schedule

i04038200 Window Wipers - Inspect/Replace ...................... 198

Windows - Clean ................................................. 198
Maintenance Interval Schedule
Every 10 Service Hours or Daily
SMCS Code: 7000
Backup Alarm - Test ............................................ 128
Ensure that all safety information, warnings and Braking System - Test ......................................... 130
instructions are read and understood before any Cab Filter (Fresh Air) - Clean/Inspect/Replace ... 131
operation or any maintenance procedures are Cooling System Coolant Level - Check .............. 138
performed. Engine Oil Level - Check .................................... 147
Fuel Tank Water and Sediment - Drain ............... 167
The user is responsible for the performance of Horn - Test .......................................................... 169
maintenance, including all adjustments, the use of Hydraulic System Oil Level - Check ................... 176
proper lubricants, fluids, filters, and the replacement Indicators and Gauges - Test .............................. 177
of components due to normal wear and aging. Failure Power Train System Oil Level - Check ............... 183
to adhere to proper maintenance intervals and Pivot Shaft Oil Level - Check .............................. 186
procedures may result in diminished performance of Seat Belt - Inspect .............................................. 191
the product and/or accelerated wear of components. Walk-Around Inspection ...................................... 196

Use mileage, fuel consumption, service hours, or Every 50 Service Hours

calendar time, WHICH EVER OCCURS FIRST,
in order to determine the maintenance intervals. Bulldozer Tilt Brace and Tilt Cylinders -
Products that operate in severe operating conditions Lubricate ........................................................... 131
may require more frequent maintenance. Refer to the Lift Cylinder Yoke Bearings - Lubricate ............... 178
maintenance procedure for any other exceptions that Ripper Linkage and Cylinder Bearings -
may change the maintenance intervals. Lubricate ........................................................... 189
Track Pins - Inspect ............................................ 195
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be Every 50 Service Hours or Weekly
performed.
Cab Filter (Recirculation) - Clean/Inspect/
Note: If Cat HYDO Advanced hydraulic oils are Replace ............................................................. 132
used, the hydraulic oil change interval is extended
to 3000 hours. S·O·S services may extend the oil Initial 250 Service Hours (or at first oil
change even longer. Consult your Caterpillar dealer change)
for details.
Power Train Oil Filters - Replace ........................ 180
When Required
Every 250 Service Hours
Battery, Battery Cable or Battery Disconnect Switch -
Replace ............................................................. 128 Belts - Inspect/Adjust/Replace ............................ 129
Camera - Clean/Adjust ....................................... 132 Engine Oil Sample - Obtain ................................ 148
Cooler Cores and A/C Condenser - Clean ......... 133 Engine Oil and Filter - Change ........................... 149
Cutting Edges and End Bits - Inspect/Replace ... 140 Equalizer Bar End Pins Oil Level - Check .......... 153
Engine Air Filter Primary and/or Secondary Element - Final Drive Oil Level - Check .............................. 156
Clean/Replace .................................................. 141 Ladder - Adjust ................................................... 177
Engine Air Precleaner - Clean ............................ 143 Track - Check/Adjust ........................................... 192
Equalizer Bar Center Pin - Measure ................... 153 Winch Fairlead Rollers - Lubricate ...................... 196
Equalizer Bar End Pins - Measure ...................... 154 Winch Oil Level - Check ..................................... 197
Ether Starting Aid Cylinder - Replace ................. 155
Fuel System - Prime ........................................... 163 Initial 500 Hours (for New Systems, Refilled
Fuses and Circuit Breakers - Replace/Reset ...... 167 Systems, and Converted Systems)
High Intensity Discharge Lamp (HID) - Replace .. 168
Hydraulic System Filter Bypass Screen - Clean .. 171 Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 138
Oil Filter - Inspect ................................................ 178
Electronic Unit Injector - Inspect/Adjust .............. 141
Radiator Core - Clean ......................................... 187
Radiator Pressure Cap - Clean/Replace ............ 187 Engine Valve Lash - Check/Adjust ...................... 152
Engine Valve Rotators - Inspect ......................... 152
Ripper Tip and Shank Protector - Inspect/
Replace ............................................................. 190
Torque Converter Scavenge Screen - Clean ...... 192 Every 500 Service Hours
Winch Wire Rope - Install ................................... 197 Engine Crankcase Breather - Clean ................... 143
Window Washer Reservoir - Fill .......................... 198 Final Drive Oil Sample - Obtain .......................... 157
SEBU7764-10 127
Maintenance Section
Maintenance Interval Schedule

Final Drive Seal Guard - Inspect/Clean .............. 158 Overhaul

Fuel System Primary Filter - Clean/Replace ....... 164
Fuel System Secondary Filter - Replace ............ 165 Fuel Lines - Replace ........................................... 161
Fuel Tank Cap Filter and Strainer -
Replace/Clean .................................................. 166
Hoses and Clamps - Inspect/Replace ................ 169
Hydraulic System Oil Filters - Replace ............... 174
Hydraulic System Oil Sample - Obtain ............... 176
Power Train Breather - Clean ............................. 179
Power Train Oil Filters - Replace ........................ 180
Power Train System Oil Sample - Obtain ........... 184
Recoil Spring Compartment Oil Level - Check ... 187

Every 1000 Service Hours or 6 Months

Battery - Inspect .................................................. 128
Power Train Oil - Change ................................... 181
Power Train System Screens - Clean ................. 185
Rollover Protective Structure (ROPS) - Inspect .. 190

Every 2000 Service Hours or 1 Year

Engine Mounts and Equalizer Bar - Inspect ....... 144
Final Drive Oil - Change ..................................... 156
Final Drive Seal Guard Packing - Replace ......... 158
Hydraulic System Oil - Change ........................... 173
Hydraulic System Oil Filter (Pilot) - Replace ....... 174
Ladder Hinge Oil - Change ................................. 178
Track Roller Frame - Inspect .............................. 195
Track Roller Frame Guides - Inspect .................. 195

Every Year
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 138
Engine Air Filter Primary and/or Secondary Element -
Clean/Replace .................................................. 141
Refrigerant Dryer - Replace ................................ 188

Every 3 Years After Date of Installation or

Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 191

Every 4000 Service Hours

Electronic Unit Injector - Inspect/Adjust .............. 141
Engine Mounts and Crankshaft Vibration Damper -
Inspect .............................................................. 144
Engine Valve Lash - Check/Adjust ...................... 152
Engine Valve Rotators - Inspect ......................... 152

Every 6000 Service Hours or 3 Years

Bearing Block Seal - Replace ............................. 129
Cooling System Coolant Extender (ELC) - Add .. 137
Cooling System Water Temperature Regulator -
Replace ............................................................. 139

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 135
128 SEBU7764-10
Maintenance Section
Backup Alarm - Test

i02035368 5. Replace the disconnect switch, the battery cables,

or the batteries, as required.
Backup Alarm - Test
6. Connect the negative battery cable at the battery.
SMCS Code: 7406-081
7. Connect the negative battery cable at the battery
disconnect switch.

8. Install the key and turn the battery disconnect

switch to the ON position.

Battery Recycle
Always recycle a battery. Never discard a battery.

Always return used batteries to one of the following

locations:

• A battery supplier
g01047701
Illustration 157
• An authorized battery collection facility
The backup alarm is located at the rear of the
machine. • Recycling facility
Turn the engine start switch to the ON position in
i02063657
order to perform the test.

Apply the service brakes. Move the transmission

Battery - Inspect
control lever to the REVERSE position. SMCS Code: 1401-040
The backup alarm should sound immediately. The
backup alarm should continue to sound until the
transmission control lever is moved to the NEUTRAL
position or to the FORWARD position.

The backup alarm has one sound level. The sound

level is not adjustable.

i02019456

Battery, Battery Cable or

Battery Disconnect Switch -
Replace Illustration 158
g01057538

SMCS Code: 1401-510; 1402-510; 1411-510 (1) Terminals and Terminal Covers
(2) Retainers
1. Turn the engine start switch key to the OFF
position. Turn all of the switches to the OFF Note: Perform the following procedures at every
position. 1000 hour interval. Check the following areas more
often, as required.
2. Turn the battery disconnect switch to the OFF
position. Remove the key. 1. Open the battery access covers. The battery
access covers are on the left and right side of the
3. Disconnect the battery cable at the battery machine next to the operator compartment.
disconnect switch. The battery disconnect switch
is inside the left engine access door. 2. Tighten the battery retainers on all batteries at
every 1000 hour interval.
4. Disconnect the negative battery cable at the
battery.
SEBU7764-10 129
Maintenance Section
Bearing Block Seal - Replace

3. Clean the top of the batteries with a clean cloth.

Keep the terminals clean and coat the terminals
with petroleum jelly. Install the terminal covers
after you coat the terminals.

1. Close the battery access cover.

i02781917

Bearing Block Seal - Replace

(RJG1-528)
SMCS Code: 1359-510-SA

In order to replace the Seals in the Bearing Block

of the Air-To-Air Aftercooler, refer to Disassembly
and Assembly, RENR3923-00, “Bearing Block
(Fan Drive) - Disassemble” and Disassembly and
Assembly, RENR3923-00, “Bearing Block (Fan Drive)
- Assemble”.
g01052245
Illustration 160
i02204803
2. Inspect the condition of the belt (6) and the
Belts - Inspect/Adjust/Replace adjustment of the belt. If the belt is cracked
or frayed, replace the belt. Use a Kent Moore
SMCS Code: 1357-025; 1357-040; 1357-510 Company BT-33-97 gauge to check the tension
of the alternator belt. Refer to the following table
If a new belt is installed, check the belt adjustment for belt tension.
after 30 minutes of operation. A belt is considered to
be used after 30 minutes of operation. Table 18
Belt Tension Belt Tension
Alternator Belt Initial Used
578 ± 111 N (130 ± 25 lb) 445 ± 44 N (100 ± 9.9 lb)

3. In order to adjust the belt tension, loosen the

adjusting locknut (3) and the mounting bolt (5).

4. Turn the nut (4) until the correct tension is reached.

5. Tighten the adjusting locknut and tighten the

mounting bolt.

6. Recheck the belt tension. If the amount of tension

is incorrect repeat the adjustment procedure.

g01052350
Illustration 159

1. Open the access door (2) and hinged plate (1) on

the right side of the engine.
130 SEBU7764-10
Maintenance Section
Braking System - Test

Air Conditioner Belt (If Equipped) i02036069

Braking System - Test

SMCS Code: 4100-081; 4267-081

Personal injury can result if the machine moves

while testing.

If the machine begins to move during test, reduce

the engine speed immediately and engage the
parking brake.

Illustration 161
g01052830 Note: The brakes will not hold the machine if you
select the “1F” gear position.
1. Open the access door (7) and hinged plate (8) on
the left side of the engine. Make sure that the area around the machine is clear
of personnel and clear of obstacles.

Test the brakes on a dry, level surface.

Fasten the seat belt before you test the brakes.

The following test is used to determine whether the

service brake is functional. This test is not intended
to determine the maximum brake holding effort. The
brake holding effort to hold the brake on this machine
will be different. This is because of variations in the
engine setting, in the power train efficiency, and in
the brake holding ability.

Compare the engine speed at the beginning of

Illustration 162
g01052915 machine movement to the engine speed of a prior
test. This will be an indication of the amount of
2. Inspect the condition of the belt (12) and the system deterioration.
adjustment of the belt. If the belt is cracked
or frayed, replace the belt. Use a Kent Moore
Company BT-33-97 gauge to check the tension
of the alternator belt. Refer to the following table
for belt tension.

Table 19
Belt Tension Belt Tension
Initial Used
578 ± 111 N (130 ± 25 lb) 445 ± 44 N (100 ± 9.9 lb)

3. In order to adjust the belt tension, loosen the

adjusting locknut (10) and the mounting bolt (11).
g01017767
Illustration 163
4. Turn the nut (9) until the correct tension is reached.

5. Tighten the adjusting locknut and tighten the 1. Start the engine.
mounting bolt.
2. Raise all attachments.
6. Recheck the belt tension. If the amount of tension
is incorrect repeat the adjustment procedure. 3. Depress the brake pedal.

4. Release the parking brake switch.

SEBU7764-10 131
Maintenance Section
Bulldozer Tilt Brace and Tilt Cylinders - Lubricate

5. While the brake pedal is depressed, move the i03423423

directional control lever to the THIRD SPEED
FORWARD position. Cab Filter (Fresh Air) -
6. Gradually increase the engine speed to full load
Clean/Inspect/Replace
speed. The machine should not move. SMCS Code: 7342-040; 7342-070; 7342-510
7. Move the throttle switch to LOW IDLE. Turn on Note: Clean the filters more often in dusty conditions.
the parking brake switch. Lower all attachments
to the ground. Apply a slight down pressure. Stop
the engine.

NOTICE
If the machine moved while testing the brakes, contact
your Caterpillar dealer. Have the dealer inspect and,
if necessary, repair the service brake before returning
the machine to operation.

i03954091

Bulldozer Tilt Brace and Tilt

Cylinders - Lubricate Illustration 165
g01049846

SMCS Code: 5104-086; 6050-086; 6074-086 1. Open the access cover to the filter element. The
filter cover is on the left side of the machine above
Lubricate the tilt cylinders and the tilt braces. the battery compartment.

2. The filter element can be cleaned by using

pressure air. Use a maximum air pressure of
205 kPa (30 psi). Direct the air from the clean side
to the dirty side.

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

the element for damage. Inspect the gaskets for
damage. Replace damaged filters.

4. Install the filter element.

RJG1840-Up
g02158909
Illustration 164

One grease fitting is located at the left front brace

assembly or left tilt cylinder (if equipped).

One grease fitting is located at the rod end of the

right tilt cylinder.

A grease fitting is located at the cylinder connection

to each push arm.

g01768834
Illustration 166

1. Loosen three clamps (2) and remove filter cover

(1). The filter cover is located outside the left side
of the cab.
132 SEBU7764-10
Maintenance Section
Cab Filter (Recirculation) - Clean/Inspect/Replace

2. Remove filter element (3). i03680600

3. The filter element can be cleaned by using Camera - Clean/Adjust

pressure air. Use a maximum air pressure of
205 kPa (30 psi). Direct the air from the clean side
(WAVS (If Equipped))
to the dirty side. SMCS Code: 7348
4. Look through the filter toward a bright light. Inspect In order to maintain sufficient vision, keep the Work
the element for damage. Inspect the gaskets for Area Vision System (WAVS) camera lens and the
damage. Replace damaged filters. display clean.
5. Install filter element (3) and install filter cover (1).
Close three clamps (2).

i02041123

Cab Filter (Recirculation) -

Clean/Inspect/Replace
SMCS Code: 7342-040; 7342-070; 7342-510

The recirculation filter is located to the left of the

operator's seat.

g01223034
Illustration 168
The WAVS display is located in the operator station.

Use a soft, damp cloth in order to clean the display.

The display has a soft plastic surface that can be
easily damaged by an abrasive material. The display
is not sealed. Do not immerse the display with
liquid.

g01049402
Illustration 167

1. Unscrew the bolt (1) in order to remove the filter

cover (2). Remove the filter element.

2. The filter element can be cleaned by using

compressed air. Use a maximum air pressure of
205 kPa (30 psi). Direct the air from the clean side
to the dirty side.
g01223051
Illustration 169
3. Look through the filter toward a bright light. Inspect
A WAVS camera is located on the rear of the machine, mounted
the element for damage. Inspect the gaskets for on top of the ROPS, or mounted on the fuel tank.
damage. Replace damaged filters.
Use a damp cloth or water spray in order to clean
4. Install the filter element. the camera lens. The camera is a sealed unit. The
camera is not affected by high pressure spray.
Note: Clean the filters more often in dusty conditions.
Note: The camera is equipped with an internal heater
to help counteract the effects of condensation, snow,
or ice.
SEBU7764-10 133
Maintenance Section
Cooler Cores and A/C Condenser - Clean

For more information on WAVS, refer to Operation 2. Remove the bolts along the manifold.
and Maintenance Manual, SEBU8157, “Work Area
Vision System”. 3. Unfasten the clamps that attach the air ducts.

4. Lift the manifolds off the aftercooler core. Lay the

i02784223
manifolds to the side.
Cooler Cores and A/C 5. Remove the bolts from the plates that are on the
Condenser - Clean bottom of the aftercooler.

SMCS Code: 1064-070; 1353-070; 1374-070; 6. Open the plates.

7320-070
7. Inspect the aftercooler.
Cooler Cores
Aftercooler RJG529-Up
The following cooler cores are cooled by the hydraulic
fan that is located in the radiator guard at the front
of the track-type tractor.

Aftercooler core – The aftercooler core cools the

inlet manifold air to the engine.

Radiator core – The AMOCS radiator cores cool

the engine coolant.

A/C condenser core – The air conditioning

condenser core cools the refrigerant in the air
conditioning system.

Aftercooler RJG1-528 g01219189

Illustration 171

Note: The remote air-to-air aftercooler core Rear view of dual aftercooler RJG529-Up
(RATAAC) that is used on machines RJG1-528 uses
a hydraulic fan that is mounted to the bottom of the Radiator Core
hood.

g00827864
Illustration 172
g01106873
Illustration 170
Left side view of aftercooler RJG1-528
(1) Hood
(2) Precleaner
(3) Aftercooler
(4) Manifold
(5) Air duct

Accessing the Remote Aftercooler Core

1. Remove the manifold.

134 SEBU7764-10
Maintenance Section
Cooler Cores and A/C Condenser - Clean

A/C Condenser Core An optional arrangement for the air conditioner

condenser is located on the right side fender.

g01060198
Illustration 173
g01117129
Illustration 176
A common arrangement for the air conditioner
condenser is located behind the radiator. An optional arrangement for the air conditioner
condenser is located on the top of the machine.

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

g01224464
Illustration 174

Another arrangement for the air conditioner

condenser is located under the hood.

Remote A/C Condenser Core

g01389572
In some machine arrangements, the a/c condenser Illustration 177
core is remotely located. A remote mounted a/c
condenser core is cooled by fans with electric drive. Turn off the engine.

Open both of engine access doors (6).

Inspect the cooling system for the following

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

Inspect the hydraulic lines to the RATAAC for chafing

and rubbing of the hoses. Replace the hydraulic
lines, if necessary.

g01053048
Illustration 175
SEBU7764-10 135
Maintenance Section
Cooling System Coolant (ELC) - Change

Note: If parts of the aftercooler system may appear Do not use steam or high pressure water for cleaning
to be damaged or if parts of the aftercooler system frequently. If steam or high pressure water is required
are repaired, a leak test is highly recommended. to dislodge any debris that is held deep in the cores,
Refer to Special Instruction, SEHS8622, “Using the make sure that the cleaning is thorough. This may
FT1984 Air-to-Air Aftercooler Leak Test Group”. The require partial removal or total removal of the air
FT-1984 Aftercooler Testing Group can be used for conditioner condenser for better access. Incomplete
aftercoolers that have hoses with an inside diameter cleaning with water may cause remaining debris to
of 102 mm (4.00 inches) or 114 mm (4.50 inches). harden in place. Use lights and wire probes in order
to ensure that the cleaning is thorough and complete.
For more detailed information on testing and If the debris has hardened in the center of the cores,
inspection, see Special Publication, SEBD0518, these cores may need to be removed for thorough
“Know Your Track-Type Tractor Cooling System”. cleaning.

Replacing the Aftercooler Core in the Top Hood If you use a degreaser and steam for removal of oil
and grease, wash the core with detergent and hot
1. Close the plates on the bottom of the aftercooler water. Thoroughly rinse the core with clean water. Dry
and attach the bolts. the cores completely before operating the machine
in the work mode.
2. Place the manifolds on the aftercooler and attach
the bolts. Dry
3. Reattach the air ducts and tighten the clamps. If steam or water is used to clean the cores, make
sure that the cores are completely dry before the
4. Reattach the access panels. track-type tractor is put back to work.

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

Close both engine access doors.

Personal injury can result from air pressure. If the machine is in a clean environment, start the
engine and allow the fan to run until the cooling
Personal injury can result without following prop- system has completely dried. Allow the machine to
er procedure. When using pressure air, wear a pro- sit overnight before operating the machine in the
tective face shield and protective clothing. work mode.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes. i02204835

Cooling System Coolant (ELC)

Radiator cores, aftercooler cores, and a/c condenser
cores needed to be cleaned regularly. Adjust the - Change
frequency of cleaning according to the effects of the
operating environment. SMCS Code: 1395-044

Blow out the cores with compressed air. Move the NOTICE
air nozzle in a systematic pattern so that the air Make sure you read and understand the information
flow covers the whole core that includes areas in in the topics Safety and Cooling System Specifica-
the corner. Clean the middle space between the tions for all information pertaining to water, antifreeze
aftercooler core and the a/c condenser core. and supplemental coolant additive requirements be-
fore you proceed with maintenance of the cooling sys-
Use a bent copper tube that is approximately 1/4 -3/8 tem.
inch diameter as an extension to the air nozzle. This
will facilitate cleaning of the middle spaces. The access door for the cooling system filler cap is
located on top of the engine enclosure on the left
side.
136 SEBU7764-10
Maintenance Section
Cooling System Coolant (ELC) - Change

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.
g01113481
Illustration 178 6. Close the drain valve and install the plug.

1. Slowly loosen filler cap in order to relieve system 7. Replace the access cover.
pressure. Remove the filler cap.
8. Add the ELC solution. Refer to Operation and
Maintenance Manual, “Capacities - Refill”.

9. Start the engine. Run the engine without the filler

cap until the thermostat opens and the coolant
level stabilizes. Check the level of the coolant.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant Level - Check”.

10. If the gasket is damaged, replace the filler cap.

Install the filler cap.

11. Stop the engine.

g01048307
Illustration 179

2. Remove the access cover for the coolant drain.

The cover is located in the front, bottom guard.

g00533931
Illustration 181

12. Clean the radiator cores with compressed air. You

may need to use water in order to remove debris.

For additional information about the coolant, see

g01113507
Illustration 180 Operation and Maintenance Manual, SEBU6250,
Bottom view “Caterpillar Machine Fluids Recommendations” or
consult your Caterpillar dealer.
3. Remove the plug from the drain valve. Install a
12.7 millimeter (.5 inch) pipe into the drain valve.
The pipe requires 1/2 - 14 NPTF threads. Clamp
a hose to the pipe in order to direct the coolant
into a suitable container.
SEBU7764-10 137
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

i02205241

Cooling System Coolant

Extender (ELC) - Add
SMCS Code: 1352-044

Table 20
Amount of the Caterpillar Extended Life Coolant
Extender by Cooling System Capacity
Cooling System Capacity Recommended
Amount of Caterpillar
Extender
115 to 163 L (30 to 43 US gal) 3.00 L (100 oz) g01113678
Illustration 182

When a Caterpillar Extended Life Coolant (ELC) 1. The access door for the radiator cap and the sight
is used, an extender must be added to the cooling glass for the coolant is located on the top left of
system. See the Operation and Maintenance the engine enclosure. Loosen the radiator cap (1)
Manual, “Maintenance Interval Schedule” for the slowly in order to relieve pressure. Remove the
proper service interval. The amount of extender is radiator cap.
determined by the cooling system capacity.
2. It may be necessary to drain some coolant from
For additional information about adding an extender, the radiator so that Extender can be added to the
see Operation and Maintenance Manual, “Model cooling system.
Specific Coolant Information” or consult your
Caterpillar dealer.
NOTICE
Use a 8T-5296 Coolant Test Kit to check the Care must be taken to ensure that fluids are contained
concentration of the coolant. during performance of inspection, maintenance, test-
ing, adjusting and repair of the machine. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
Personal injury can result from hot coolant, steam
and alkali. Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide”, for tools and sup-
At operating temperature, engine coolant is hot plies suitable to collect and contain fluids in Caterpillar
and under pressure. The radiator and all lines machines.
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns. Dispose of all fluids according to local regulations and
mandates.
Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool
enough to touch with your bare hand. 3. Add 3.00 L (100 oz) of Extender to the cooling
system.
Cooling System Conditioner contains alkali. Avoid
contact with skin and eyes. 4. Observe the sight glass (2) in order to verify the
level of coolant. If the coolant level is at the middle
of the sight glass, the coolant level is correct. If
the coolant level is below the middle of the sight
glass, the coolant level is low.

5. Replace the radiator cap if the cap gasket is

damaged. Install the radiator cap.
138 SEBU7764-10
Maintenance Section
Cooling System Coolant Level - Check

i02205428 5. Inspect the radiator core for debris. Clean the

radiator core, if necessary.
Cooling System Coolant Level
- Check Use compressed air, high pressure water, or steam
to remove dust and debris from the radiator core.
SMCS Code: 1353-535-FLV; 1395-535-FLV However, the use of compressed air is preferred.

i02319439

At operating temperature, the engine coolant is Cooling System Coolant

hot and under pressure. Sample (Level 2) - Obtain
Steam can cause personal injury. SMCS Code: 1350-008; 1395-008; 1395-554; 7542

Check the coolant level only after the engine has

been stopped and the fill cap is cool enough to Level 2 Analysis
touch with your bare hand.
NOTICE
Remove the fill cap slowly to relieve pressure. Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Cooling system conditioner contains alkali. Avoid Using the same pump for both types of samples may
contact with the skin and eyes to prevent personal contaminate the samples that are being drawn. This
injury. contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
The access door for the radiator cap and the sight
glass for the coolant is located on the top left of the
engine enclosure. NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.
g01113678
Illustration 183
Testing the coolant can be done at your Caterpillar
dealer. Caterpillar S·O·S Coolant Analysis is the best
1. Observe the sight glass (2) in order to verify the way to monitor the condition of your coolant and your
level of the coolant. If the coolant is above the cooling system. S·O·S Coolant Analysis is a program
middle of the sight glass, the coolant level is
that is based on periodic samples. See Operation
correct. If the coolant level is below the middle of and Maintenance Manual, SEBU6250, “Caterpillar
the sight glass, the coolant level is low. Machine Fluid Recommendations”, “S.O.S Coolant
Analysis” for more information.
2. If it is necessary to add coolant, remove the
radiator cap (1) slowly in order to relieve the Perform a Coolant Analysis (Level 2) at the initial 500
pressure.
hours. Perform the analysis yearly after the initial
500 hours.
3. Inspect the radiator cap and the radiator cap seal
for debris, for foreign material, or for damage.
Use the following guidelines for proper sampling of
Clean the radiator cap with a clean cloth. Replace the coolant:
the radiator cap if the radiator cap is damaged.

4. Install the radiator cap.

SEBU7764-10 139
Maintenance Section
Cooling System Water Temperature Regulator - Replace

• Complete the information on the label for the 2. The sampling valve for the coolant is located on
sampling bottle before you begin to take the the right side of the engine. Remove the protective
samples. cap from the sampling valve.

• Keep the unused sampling bottles stored in plastic 3. Use a 169-8373 Fluid Sampling Bottle in order
bags. to obtain a sample.

• Obtain coolant samples directly from the coolant 4. Replace the protective cap.
sample port. You should not obtain the samples
from any other location. Submit the sample for Level 2 analysis.

• Keep the lids on empty sampling bottles until you i02050545

are ready to collect the sample.
Cooling System Water
• Place the sample in the shipping sleeve
immediately after obtaining the sample in order to Temperature Regulator -
avoid contamination.
Replace
• Never collect samples from expansion bottles. SMCS Code: 1355-510
• Never collect samples from the drain for a system. Replace the temperature regulators on a regular
basis in order to reduce the chance of unscheduled
1. Park the machine on a hard, level surface. Set the
downtime and of problems with the cooling system.
engine at low idle speed.
The temperature regulators should be replaced after
the cooling system has been cleaned. Replace the
temperature regulators while the cooling system
is completely drained or while the cooling system
coolant is drained to a level that is below the regulator
housing.

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

NOTICE
Illustration 184
g01048147 Replace the thermostat on a regular basis in order to
reduce the chance of unscheduled downtime and of
RJG1-528
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.

g01218874
Illustration 185
RJG529-Up
Right side view
140 SEBU7764-10
Maintenance Section
Cutting Edges and End Bits - Inspect/Replace

NOTICE
Personal injury can result from hot coolant, steam If the thermostat is installed incorrectly, it will cause
and alkali. the engine to overheat.

At operating temperature, engine coolant is hot 5. Install new seals and install new temperature
and under pressure. The radiator and all lines regulators. Install a new housing gasket.
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns. 6. Install the regulator housing and install the elbows.
Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool i03204387
enough to touch with your bare hand.
Cutting Edges and End Bits -
Do not attempt to tighten hose connections when Inspect/Replace
the coolant is hot, the hose can come off causing
burns. SMCS Code: 6801-040; 6801-510; 6804-040;
6804-510
Cooling System Conditioner contains alkali. Avoid
contact with skin and eyes.

g01051836
Illustration 187

Illustration 186
g01051918 1. Raise the bulldozer blade and block up the
bulldozer blade. When you remove the cutting
1. The housing for the temperature regulators is edges and the end bits, maintain the bulldozer
located on the front of the engine. blade at a minimum height.

2. Remove the bolts (1) and (3) from the elbows. 2. Remove the bolts. Then remove the cutting edge
Remove the elbows. and the end bits.

3. Remove the bolts (2) from the temperature 3. Thoroughly clean all contact surfaces.
regulator housing.
4. Inspect the opposite side of the cutting edge. If
4. Remove the two temperature regulators and the the opposite side of the cutting edge is not worn,
seals. turn the opposite side of the cutting edge outward
and install the cutting edge.
NOTICE
5. If both sides of the cutting edge are worn, install a
Since Caterpillar engines incorporate a shunt design
new cutting edge section.
cooling system, it is mandatory to always operate the
engine with a thermostat.
Note: When the cutting edge is within 10 mm
(0.4 inch) of the bottom of the support, change the
Depending on load, failure to operate with a thermo-
cutting edge. Do not allow wear to occur on the
stat could result in either an overheating or an over-
support.
cooling condition.
6. If the bottom edge or the outside edge of the end
bit is worn, install a new end bit.
SEBU7764-10 141
Maintenance Section
Electronic Unit Injector - Inspect/Adjust

Note: When the end bit is within 10 mm (0.4 inch) of i03619440

the bottom of the support, change the end bit. When
the end bit is within 10 mm (0.4 inch) of the outside Engine Air Filter Primary
edge of the support, change the end bit. Do not
allow any wear to occur on the support.
and/or Secondary Element -
Clean/Replace
7. Install all bolts and tighten the bolts to the specified
torque. SMCS Code: 1054-070-SE; 1054-070-PY;
1054-510-SE; 1054-510-PY
Reference: For more information, refer to
Specifications, “Torque Specifications”. Primary Filter
8. Raise the bulldozer blade and remove the
blocking. Lower the bulldozer blade to the ground. NOTICE
Service the primary filter element only when the alert
9. After you operate the machine for a few hours, indicator for the intake air filter is flashing. Do not open
check all bolts for the proper torque. the filter compartment unless it is time for service.
Opening the filter compartment can cause dirt to get
into the clean side of the filter housing.
i02061807

Electronic Unit Injector - NOTICE

Inspect/Adjust Extremely short air filter life can result if the preclean-
er system malfunctions. If air filter life is drastically re-
SMCS Code: 1290-025; 1290-040 duced from typical for the operating conditions, con-
sult your Caterpillar Dealer. The exhaust system dust
ejector for the strata tube precleaner must pull a min-
imum vacuum of 508 mm (20 inch) of water.

The Electronic Control module produces high

voltage. To prevent personal injury make sure the NOTICE
Electronic Control Module is not powered and the Service the engine air filters with the engine stopped.
unit injector solenoids are disconnected. Engine damage could result.

NOTICE NOTICE
The camshafts must be correctly timed with the crank- Always leave the secondary filter element in place
shaft before an adjustment of the unit injector lash while you clean the primary element, or while you
is made. The timing pins must be removed from the clean the air cleaner housing.
camshafts before the crankshaft is turned or damage
to the cylinder block will be the result.
NOTICE
Do not use the filter for longer than one year.
The operation of Caterpillar engines with improper
adjustments of the electronic unit injector can reduce
engine efficiency. This reduced efficiency could result 1. Open the engine compartment's access door, if
in excessive fuel usage and/or shortened engine equipped.
component life.

Adjust the electronic unit injector at the same interval

as the valve lash adjustment.

Refer to your machine's Service Manual or your

Caterpillar dealer for the complete adjustment
procedure.

g00470852
Illustration 188
142 SEBU7764-10
Maintenance Section
Engine Air Filter Primary and/or Secondary Element - Clean/Replace

2. Remove the air cleaner cover (1). Pull out in order 9. Push the filter element firmly in order to properly
to remove the element. seat the element. Write the date on the element, if
the primary element is replaced.
3. Remove the primary filter element (2) from the air
cleaner housing. 10. Install the air cleaner cover.

4. Mark the secondary filter element in order to show 11. Close the access door, if equipped.
that the primary filter element has been serviced.
The secondary filter element should be replaced
when the primary filter element is serviced for the
Secondary Filter
third time. Refer to the section “Secondary Filter”.
NOTICE
Always replace the secondary filter element. Never
attempt to reuse it by cleaning.

The secondary filter element should be replaced at the

time the primary element is serviced for the third time.

The secondary filter element should also be replaced

if the yellow piston in the filter element indicator en-
ters the red zone after installation of a clean primary
element, or if the exhaust smoke is still black.

NOTICE
The filter should be kept in service for no longer than
Illustration 189
g00470857 one year.

5. Clean the inside of the air cleaner housing. Keep

the secondary filter element in place while you NOTICE
clean the housing. Always leave the secondary filter element in place
while you clean the air cleaner housing.
6. If the primary filter element has not been cleaned
six times, inspect the primary filter element. If 1. Open the engine access door, if equipped.
the primary filter element has been cleaned six
times, replace the primary filter element. Proceed 2. Remove the air cleaner housing cover.
to Step 9.
3. Remove the primary filter element. Refer to the
7. Inspect the primary filter element. Inspect the section “Primary Filter”.
filter element for holes and for tears by looking
through the filter element. Look toward a bright 4. Clean the inside of the air cleaner housing.
light. Inspect the element for damaged gaskets or
for dented metal parts. Replace damaged filters.
Always crush damaged filter elements. Properly
discard the filter elements. If you replace the
primary filter element, proceed to step 9.

8. If the primary filter element is not damaged and

the element has not been previously cleaned six
times, clean the element. The filter element can
be cleaned by using pressure air. Use a maximum
air pressure of 205 kPa (30 psi). Direct the air
from the clean side to the dirty side. In order to
show that the filter element has been cleaned,
mark the element. The primary filter element can
be cleaned up to six times.
g00470240
Illustration 190
NOTICE
Do not clean the filter elements by bumping or tapping 5. Remove the secondary filter element. Pull out in
them. Do not use filter elements with damaged pleats, order to remove the element.
gaskets, or seals. Do not wash the filter elements.
SEBU7764-10 143
Maintenance Section
Engine Air Precleaner - Clean

6. Install a new secondary filter element. Push

the element firmly in order to properly seat the
element. Write the date on the element, if the
element is replaced.

7. Install the primary filter element and the air cleaner

housing cover.

8. Close the engine access door, if equipped.

i02053630

Engine Air Precleaner - Clean

SMCS Code: 1050-070; 1055-070

g01389603
Illustration 192
Top view

1. Remove hose (1) from the outlet of the breather

(2) on each side of the engine.

Note: Perform steps 2 through 8 on each crankcase

breather.
g01053125
Illustration 191 2. Remove bolts (3) at the base of the breather (not
shown). Remove the breather from the engine.
Inspect the air inlet screen for dirt and for trash.
3. Check the condition of the seal. Replace the seal
1. Remove the screen. Clean the screen if the if the seal is damaged.
screen is dirty.
4. Remove the breather element. Wash the breather
2. Inspect the precleaner tube for dirt and for dust. element and the breather in a clean nonflammable
solvent.
3. Clean the precleaner tube with pressure air if the
precleaner tube is dirty. 5. Shake the breather element until the breather
element is dry. You may also use pressure air to
NOTICE dry the breather element.
Service the air cleaner only with the engine stopped.
Engine damage could result. 6. Check the condition of the hose. Replace the hose
if the hose is damaged.
Run the engine at high idle. If the engine air filter 7. Install the element into the breather and install the
indicator still flashes, service the air filter. Stop the breather.
engine.
8. Install the hose onto the outlet of the breather
cover and tighten the clamp.
i02781929

Engine Crankcase Breather -

Clean
SMCS Code: 1317-070

The crankcase breathers are located on the top of

the engine.
144 SEBU7764-10
Maintenance Section
Engine Mounts and Crankshaft Vibration Damper - Inspect

i02091921 Caterpillar recommends checking the engine mounts

for deterioration. This will prevent excessive engine
Engine Mounts and Crankshaft vibration that is caused from improper mounting.
Vibration Damper - Inspect
i02195435
SMCS Code: 1152-040; 1205-040
Engine Mounts and Equalizer
Damage to the vibration damper or failure of the
vibration damper will increase torsional vibrations. Bar - Inspect
These vibrations will result in damage to the
crankshaft and in damage to the other engine SMCS Code: 1152-040; 7206-040
components. A deteriorating vibration damper will
cause excessive gear train noise at variable points Engine Mounts
in the speed range.
Caterpillar recommends checking the engine mounts
See the Service Manual, “Engine Disassembly and for deterioration. This will prevent excessive engine
Assembly” for the procedure to install a new damper. vibration that is caused from improper mounting.

Caterpillar recommends replacing the damper for any

of the following reasons: Equalizer Bar End Pins

• The engine has had a failure because of a broken

crankshaft.
Personal injury or death can occur from not fol-
The damper can be used again if none of the above lowing the proper procedure or the recommended
conditions are found. The damper can be used if the tooling.
damper is not damaged.
To prevent the possibility of injury or death, follow
In the damper, a wobble can occur on the outer ring. the established procedure using the recommend-
Some of the wobble of the outer ring is normal. If a ed tooling.
wobble is present, replacement of the damper is not
necessary. You can confirm an acceptable wobble by
seeing the Service Manual, “Engine Disassembly and NOTICE
Assembly” for the procedure to check the damper. The machine must be parked on a level surface to
perform this procedure.

Personal injury or death can occur from not fol-

lowing the proper procedure or the recommended
tooling.

To prevent the possibility of injury or death, follow

the established procedure using the recommend-
ed tooling.

NOTICE
Illustration 193
g01066628 The machine must be parked on a level surface to
perform this procedure.
Marks of the damper are on the hub and on the
ring. These marks will indicate the condition of the Note: All the weight of the machine must be removed
vibration damper. If the marks are not in alignment, from the equalizer bar. Equalizer bar must have free
the rubber seal between the ring and the hub has movement in order to be measured.
separated from the ring and/or from the hub. Install a
new damper if the marks are not in alignment . To check the equalizer bar end pin for movement and
unusual wear, perform the following steps.
Note: Refer to the Service Manual, “Engine
Disassembly and Assembly” for the necessary
replacement procedure.
SEBU7764-10 145
Maintenance Section
Engine Mounts and Equalizer Bar - Inspect

g01108793 g01108798
Illustration 194 Illustration 196

1. Clean the areas that are around the end pin with a 5. Put a 55 ton hydraulic jack in position under the
high pressure wash. Inspect the condition of the end of the equalizer bar.
seal.
6. Jack up the equalizer bar and take a reading on
2. Check the area for oil leakage and a neutral seal the dial indicator in order to determine the amount
position. of wear.

3. Check the oil in both end pin joints. Note: Schedule the end pin joint for repair if the
reading on the dial indicator exceeds 1.50 mm
(.059 inch).

7. Repeat the inspection and the measurement

procedure for the other end of the equalizer bar
and end pin.

Consult your Caterpillar dealer for an inspection and

for repair instructions.

Equalizer Bar Center Pin

Personal injury or death can occur from not fol-

lowing the proper procedure or the recommended
tooling.

To prevent the possibility of injury or death, follow

the established procedure using the recommend-
ed tooling.

NOTICE
The machine must be parked on a level surface to
perform this procedure.
g01108795
Illustration 195

4. Position a dial indicator on the bracket for the pin

on the roller frame. Set the dial indicator probe
on top of the equalizer bar. Set the dial indicator
to zero.
146 SEBU7764-10
Maintenance Section
Engine Mounts and Equalizer Bar - Inspect

Personal injury or death can occur from not fol-

lowing the proper procedure or the recommended
tooling.

To prevent the possibility of injury or death, follow

the established procedure using the recommend-
ed tooling.

NOTICE
The machine must be parked on a level surface to
perform this procedure.
g01108804
Illustration 199
Note: All the weight of the machine must be removed
from the equalizer bar. Equalizer bar must have free 3. Position a dial indicator on the equalizer bar
movement in order to be measured. and place the probe of the dial indicator under
the center of the frame for the pin. Set the dial
To check the equalizer bar center pin for looseness indicator to zero.
and for unusual wear, perform the following steps.
4. Jack up the front of the machine until the weight
of the roller frames are supported by the equalizer
bar.

5. Take a reading of the dial indicator in order to

determine the amount of wear on the pin and
bearing.

Note: Schedule the center pin joint for repair if

movement exceeds 2.54 mm (.100 inch).

Consult your Caterpillar dealer for an inspection and

for repair instructions.

g01108801 Equalizer Bar Pads

Illustration 197

1. Clean the areas that are around the center pin

and equalizer bar.

g01108806
Illustration 200

The equalizer bar pads are under the front guard,

g01108803 which is underneath the machine. Inspect the
Illustration 198
equalizer bar pads for cracked rubber and for missing
portions of rubber. Consult your Caterpillar dealer for
2. Put a 55 ton hydraulic jack in position under the replacement parts and for replacement instructions.
main frame, as shown.
SEBU7764-10 147
Maintenance Section
Engine Oil Level - Check

i02438636 Note: Your machine is equipped with one of the two

dipsticks that are shown.
Engine Oil Level - Check
SMCS Code: 1302-535-FLV; 1326-535-FLV

Hot oil and components can cause personal in-

jury.

Do not allow hot oil or components to contact

skin.

NOTICE
Do not under fill or overfill engine crankcase with oil.
g01223388
Either condition can cause engine damage. Illustration 203
(A) Full mark at the engine running position(“LOW IDLE”)

g01047439
Illustration 201 g01218685
Illustration 204
1. Open the access cover on the left side of the (B) Full mark with cold engine oil (“ENGINE STOPPED”)
machine.
2. Check the “SAFE OPERATING RANGE” side
or the “LOW IDLE” side of dipstick (1) while the
engine is running at low idle. The oil should be
at operating temperature. Maintain the oil level to
the “FULL” mark.

Check the “SAFE STARTING RANGE” side or the

“ENGINE STOPPED” side of dipstick (1) before
starting the engine when the engine oil is cold.
Maintain the oil level to the “FULL” mark.

Note: When you operate the machine on severe

slopes, the oil level in the engine crankcase must be
in the “SAFE OPERATING RANGE” zone or “LOW
IDLE” zone of the dipstick.

3. Remove oil filler cap (2). If necessary, add oil.

4. Clean the oil filler cap and install the oil filler cap.

5. Close the access cover.

g01218549
Illustration 202
148 SEBU7764-10
Maintenance Section
Engine Oil Sample - Obtain

i02449892 • Keep the lids on empty sampling bottles until you

are ready to collect the sample.
Engine Oil Sample - Obtain
• Place the sample in the mailing tube immediately
SMCS Code: 1000-008; 7542-008 after obtaining the sample in order to avoid
contamination.

• Never collect samples from the drain for a system,

Hot oil and components can cause personal in- a pan of used oil or a used filter.
jury.
1. Operate the machine until the machine reaches
Do not allow hot oil or components to contact operating temperature.
skin.
2. Set the engine at low idle.

NOTICE 3. Open the access cover (if equipped) that is on the

Care must be taken to ensure that fluids are contained left side of the machine.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

Obtain the sample of the engine oil as close as Illustration 205

g01223047
possible to the recommended sampling interval.
The sampling interval may vary for some S·O·S oil 4. Clean the area around the sampling valve and the
analysis programs. In order to receive the full effect protective cap in order to avoid contamination of
of S·O·S oil analysis, you must establish a consistent the sample. Remove the protective cap.
trend of data. In order to establish a pertinent history
of data, perform consistent oil samplings that are 5. Flush the sampling valve. Insert the probe into the
evenly spaced. sampling valve. Collect about 100 mL (4 oz) of oil
into a container. This will flush the sampling valve.
Supplies for collecting samples can be obtained Remove the probe.
from your Caterpillar dealer. These supplies include
the following: probes, probe holders, tubing, and Note: It may be necessary to increase the engine
sampling bottles. RPM if the oil flow is too slow at low idle.
Use the following guidelines for proper oil sampling: 6. Collect the sample. Do not allow dirt or other
contaminants to enter the sampling bottle. Insert
• Always take samples when the machine is at the probe into the sampling valve and fill the
operating temperature and the oil has had time in sampling bottle three-fourths from the top. Do not
order to circulate through the oil system. fill the bottle completely.

• Always drain about 100 mL (4 oz) of oil into a 7. Remove the probe from the sampling valve. Put
container before you take the sample. This will the cap securely on the sampling bottle. Place the
flush the sampling valve. sampling bottle with the completed label into the
mailing tube.
• Complete the information on the label for the
sampling bottle before you begin to take the 8. Replace the protective cap on the sampling valve.
samples.
9. Close the access cover (if equipped).
• Keep the unused sampling bottles stored in plastic
bags.
SEBU7764-10 149
Maintenance Section
Engine Oil and Filter - Change

i03968510 Table 21

Engine Oil and Filter - Change D10T Series

Engine Oil Change Interval(1)
SMCS Code: 1308-510; 1318-510 Operating Conditions
Severe
Selection of the Oil Change Interval
Fuel Altitude
Multigrade High Sulfur above
NOTICE Oil Type Normal(2) Load above 1830 m
Care must be taken to ensure that fluids are contained Factor(3) 0.3% (6000
during performance of inspection, maintenance, test- (4) ft)
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- Cat DEO
500 hr 500 hr 250 hr 250 hr(6)
Preferred
nent containing fluids.
ECF-2
500 hr 500 hr 250 hr 250 hr(6)
Refer to Special Publication, NENG2500, “Caterpillar Preferred
Dealer Service Tool Catalog” for tools and supplies
150
suitable to collect and contain fluids on Caterpillar ECF-1-a 250 hr 250 hr
hr(5)
250 hr(6)
products.
(1) The traditional oil change interval for engines is 250 hours.
The standard oil change interval in this machine is 500 hours, if
Dispose of all fluids according to local regulations and the operating conditions and recommended oil types that are
mandates. listed in this table are met. Improvements in the engine allow
this engine oil change interval. This new standard interval is not
permitted for other machines. Refer to the applicable Operation
NOTICE and Maintenance Manuals for the other machines.
This machine is equipped with an engine that meets (2) Normal conditions include these factors: Fuel sulfur below

EPA Tier 3, Euro Stage III, or MOC Step 3 emission 0.3%, altitude below 1830 m (6000 ft), and good air filter and
fuel filter maintenance. Normal conditions do not include high
regulations. A 500 hour engine oil change interval is load factor, harsh operating cycles, or harsh environments.
available, provided that operating conditions and rec- (3) Load factors are defined as a function of fuel consumption rate.
ommended multigrade oil types are met. When these High load factors can shorten the service life of your engine oil.
requirements are not met, shorten the oil change Continuous heavy load cycles and very little idle time result
interval to 250 hours, or use an S·O·S oil sampling in increased fuel consumption and oil contamination. These
factors deplete the oil additives more rapidly. If the average
and analysis program to determine an acceptable oil fuel consumption of your D10T exceeds 76 L (20.1 US gal)
change interval. per hour, follow the “High Load Factor” recommendations in
Table 21. To determine average fuel consumption, measure
If you select an interval for oil and filter change that is average fuel consumption for a period of 50 to 100 hours. If
too long, you may damage the engine. the application of the machine is changed, the average fuel
consumption may change.
(4) For sulfur content above 0.1%, refer to this topic in the Manual,
SEBU6250.
CAT oil filters are recommended. (5) In order to verify an oil change interval of 500 hours, refer to
“Program A” below.
Recommended multigrade oil types are listed in (6) Use “Program B” below to determine an appropriate interval.
Table 21.

Note: Do not use API CF-4 oils in Caterpillar

Adjustment of the Oil Change Interval
machine diesel engines.
Note: Your Cat dealer has additional information on
these programs.
Abnormally harsh operating cycles or harsh
environments can shorten the service life of
Program A
the engine oil. Arctic temperatures, corrosive
environments, or extremely dusty conditions
Verification for an Oil Change Interval of 500 Hours
may require a reduction in engine oil change
intervals from the recommendations in Table 21.
Also refer to Manual, SEBU5898, “Cold Weather
Recommendations for all Caterpillar Machines”.
Poor maintenance of air filters or of fuel filters
requires reduced oil change intervals. See your
Cat dealer for more information if this product will
experience abnormally harsh operating cycles or
harsh environments.
150 SEBU7764-10
Maintenance Section
Engine Oil and Filter - Change

This program consists of three oil change intervals of Procedure for Changing the Engine
500 hours. Oil sampling and analysis is done at 250
hours and 500 hours for each of the three intervals
Oil and Filter
for a total of six oil samples. The analysis includes
oil viscosity and infrared (IR) analysis of the oil. If
all of the results are satisfactory, the 500 hour oil
change interval is acceptable for the machine in that
application. Repeat Program A if you change the
application of the machine.

If a sample does not pass the oil analysis, take one

of these actions:

• Shorten the oil change interval to 250 hours.

• Proceed to Program B.
• Change to a preferred oil type in Table 21. Illustration 206
g01051084

Program B 1. Open the engine access door on the left side of

the machine.
Optimizing Oil Change Intervals

Begin with a 250 hour oil change interval. The oil

change intervals are adjusted by increments. Each
interval is adjusted an additional 50 hours. Periodic oil
sampling and analysis is done during each interval.
The analysis includes oil viscosity and infrared (IR)
analysis of the oil. Repeat Program B if you change
the application of the machine.

If an oil sample does not pass the analysis, shorten

the oil change interval, or change to a preferred
multigrade oil type in the listing above.

References
g01047383
Illustration 207
Reference: Form, PEDP7035, “Optimizing Oil
Change Intervals” 2. If the machine is equipped with a high speed oil
change arrangement, use a nozzle assembly in
Reference: Form, PEDP7036, “S·O·S Fluid Analysis” order to drain the oil from the crankcase.

Reference: Form, PEHP7076, “Understanding the

S·O·S Oil Analysis Tests”

g01051220
Illustration 208

3. The access cover for the crankcase drain is

located in the belly guard underneath the front of
the machine. Remove the bolt in order to remove
the access cover.
SEBU7764-10 151
Maintenance Section
Engine Oil and Filter - Change

Instructions for the installation of the filters are

printed on the side of each Caterpillar spin-on
filter. For non-Caterpillar filters, refer to the
installation instructions that are provided by the
supplier of the filter.

9. Install the crankcase drain plug.

10. Remove oil filler cap (7). Fill the crankcase with
new oil. See Operation and Maintenance Manual,
“Capacities (Refill)”. Clean the oil filler cap and
install the oil filler cap.

11. Always measure the oil level with dipstick (6) in

g01047321
order to ensure that the correct amount of oil was
Illustration 209 added.
4. Open the crankcase drain valve. Allow the oil to 12. Start the engine in order to warm the oil.
drain into a suitable container. A drain hose may
be attached to the crankcase drain valve in order Note: Your machine is equipped with one of the two
to aid the draining of the oil. dipsticks that are shown.
5. When the oil has been completely drained from
the crankcase, close the crankcase drain valve.
Close the crankcase drain access cover.

g01223388
Illustration 211
(A) Full mark at the engine running position (“LOW IDLE”)

13. Check the “SAFE OPERATING RANGE” side

or the “LOW IDLE” side of the dipstick while the
engine is running. The oil should be at operating
temperature. Maintain the oil level in the “SAFE
OPERATING RANGE” or the “LOW IDLE” range.

14. Close the engine access door on the left side of

g01222997
Illustration 210 the machine.

6. Remove the crankcase oil filter elements (5) and

discard the crankcase oil filter elements properly.
Make sure that all of the old filter seals are
removed from the filter base.

7. Apply a thin film of clean engine oil to the sealing

surface of the new filter element.

8. Install the new oil filter elements by hand.

152 SEBU7764-10
Maintenance Section
Engine Valve Lash - Check/Adjust

i02092049

Engine Valve Lash -

Electrical shock hazard. The electronic unit injec-
Check/Adjust tor system uses 90-120 volts.
SMCS Code: 1102-025

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 mea-
suring valve clearance.

Electrical shock hazard. The electronic unit injec- Illustration 212

g00941949
tor system uses 90-120 volts.
1. Start the engine. Run the engine at low idle.
NOTICE
Operation of Caterpillar engines with improper valve
adjustments will reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life.

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

Check the valve bridge before setting the valve lash.

g00038585
Ensure that the valve bridge is seated equally on Illustration 213
both valve stems.
2. Watch the top surface of each valve rotator.
Refer to your machine's Service Manual or your Whenever an inlet valve closes or an exhaust
Caterpillar dealer for the complete valve adjustment valve closes, each valve rotator should turn.
procedure.
3. If a valve rotator fails to rotate, consult your
Caterpillar dealer for service.
i02092057
Note: Caterpillar recommends replacing valve
Engine Valve Rotators - Inspect rotators that are operating improperly. An improperly
operating valve rotator will shorten valve life because
SMCS Code: 1109-040
of accelerated wear on the valves.

Note: If a damaged valve rotator is not replaced,

some valve face guttering could result. Metal particles
When inspecting the valve rotators, protective from the valve could fall into the cylinder. This could
glasses or face shield and protective clothing cause damage to the piston head and to the cylinder
must be worn, to prevent being burned by hot oil head.
or spray.
SEBU7764-10 153
Maintenance Section
Equalizer Bar Center Pin - Measure

i02092065 i02827491

Equalizer Bar Center Pin - Equalizer Bar End Pins Oil

Measure Level - Check
SMCS Code: 7206-082
(Waste Handling Arrangement)
SMCS Code: 7206-535-FLV

Note: If your machine is equipped with this

arrangement, perform this procedure every 250
service hours.

g01066674
Illustration 214
Rear view

To check the equalizer bar center pin for looseness

and for unusual wear, perform the following steps.
g00519704
Illustration 216
Note: All the weight of the machine must be removed
7H-1680 Lubrication Pump
from the equalizer bar. Equalizer bar must have free
movement in order to be measured.

1. Clean the areas that are around the center pin

with a high pressure wash.

g00736127
Illustration 215
Front view
g00304125
Illustration 217
2. Install a dial indicator and measure the vertical Equalizer bar end pin for (S/N: 3KR617-Up) machines
play in the center pin joint.
1. Clean the area that surrounds the end pin with
Note: Schedule the center pin joint for repair if a high pressure washer. Inspect the condition of
movement exceeds 2.54 mm (.100 inch). seal (1).

Consult your Caterpillar dealer for an inspection and 2. Check the area around the seal for oil leakage.
for repair instructions. Check the seal for a neutral seal position.

3. Remove plug (2).

154 SEBU7764-10
Maintenance Section
Equalizer Bar End Pins Oil Level - Check

4. Apply the gear oil through fitting (3). Fill with gear
oil until the gear oil reaches oil level (4) at the
top of the hex head on the fitting. Remove any
excess oil. This will maintain a volume of air. Refer
to Caterpillar Machine Fluids Recommendation,
SEBU6250 for the appropriate oil viscosity that is
suited to the ambient air temperature. The gear
oil must be applied with a 7H-1680 Lubrication
Pump or a suitable grease gun. Use SAE 90 API
GL-5 gear oil, 85W90 API GL-5 gear oil, 80W90
API GL-5 gear oil, or 75W90 API GL-5 gear oil.
The gear oil has excellent load carrying capacity.

5. Install plug (2).

Note: THE USE OF GREASE (MPGM) IS ONLY

ALLOWED FOR A FAILED SEAL. THE SEAL
SHOULD BE REPLACED AS SOON AS POSSIBLE.
THE COMBINATION OF GEAR OIL AND MPGM IS
NOT HARMFUL TO THE MACHINE.

g01054288
Illustration 219
i02827490

Equalizer Bar End Pins Oil 2. Check the oil level and fill oil reservoir (2). Remove
the oil filler cap in order to add the oil to the oil
Level - Check reservoir.
(If Equipped)
i02093902
SMCS Code: 7206-535-FLV
Equalizer Bar End Pins -
Note: If your machine is equipped with this
arrangement, perform this procedure every 10 Measure
service hours or daily, which ever occurs first.
SMCS Code: 7206-082

g01054187
Illustration 218 g00517058
Illustration 220

1. Open the access door on the left side of the cab. To check the equalizer bar end pin for movement and
unusual wear, perform the following steps.

Note: All weight of the machine must be removed

from the equalizer bar. Equalizer bar must have free
movement in order to be measured.

1. Clean the areas that are around the end pin with a
high pressure wash. Inspect the condition of the
seal.
SEBU7764-10 155
Maintenance Section
Ether Starting Aid Cylinder - Replace

2. Check the area for oil leakage and a neutral seal

position.

3. Install a dial indicator and measure the vertical

play at both end pin joints.

4. Check the oil in both end pin joints.

Note: Schedule the end pin joint for repair if

movement exceeds 1.50 mm (.059 inch).

Consult your Caterpillar dealer for an inspection and

for repair instructions.

i02210190 g01053343
Illustration 221

Ether Starting Aid Cylinder - 1. Open the access door on the left side of the
Replace machine (1).

SMCS Code: 1456-510-CD

Breathing ether vapors or repeated contact of

ether with skin can cause personal injury. Person-
al injury may occur from failure to adhere to the
following procedures.

Use ether only in well ventilated areas.

Do not smoke while changing ether cylinders.

Use ether with care to avoid fires.

Do not store replacement ether cylinders in living

areas or in the operator's compartment.

Do not store ether cylinders in direct sunlight or

at temperatures above 49 °C (120 °F).
g01053304
Illustration 222
Discard cylinders in a safe place. Do not puncture
or burn cylinders. 2. Loosen the cylinder retaining clamp (2). Unscrew
the empty ether starting aid cylinder (3) and
Keep ether cylinders out of the reach of unautho- remove the cylinder.
rized personnel.
3. Remove the used gasket. Install the new gasket
To avoid possible injury, be sure the brakes are ap- that is provided with each new cylinder.
plied and all controls are in Hold or Neutral when
starting the engine. 4. Install the new cylinder. Tighten the cylinder
by hand. Tighten the cylinder retaining clamp
securely.

5. Close the engine access door.

156 SEBU7764-10
Maintenance Section
Final Drive Oil - Change

i01834830 4. Inspect the drain plug seal. Replace the drain plug
seal if the drain plug seal is damaged.
Final Drive Oil - Change
5. Clean drain plug (3) and install the drain plug.
SMCS Code: 4050-535-FLV
6. Remove oil filler plug (2).

7. Fill the final drive with oil to the bottom of the filler
Hot oil and components can cause personal in- plug opening. See Operation and Maintenance
jury. Manual, “Refill Capacities”.

Do not allow hot oil or components to contact 8. Inspect the condition of the plug seal. Replace the
skin. plug seal if the plug seal is damaged.

9. Repeat Step 1 to Step 8 in order to change the oil

NOTICE in the other final drive.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the machine. Be prepared i01834822

to collect the fluid with suitable containers before

opening any compartment or disassembling any com-
Final Drive Oil Level - Check
ponent containing fluids. SMCS Code: 4050-535-FLV
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide”, for tools and sup-
plies suitable to collect and contain fluids in Caterpillar
machines. Hot oil and components can cause personal in-
jury.
Dispose of all fluids according to local regulations and
mandates. Do not allow hot oil or components to contact
skin.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the machine. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide”, for tools and sup-
plies suitable to collect and contain fluids in Caterpillar
machines.

Dispose of all fluids according to local regulations and

mandates.

g00937318
Illustration 223

1. Position one final drive so that oil level mark (1) is

horizontal. Drain plug (3) should face downward.

2. Remove drain plug (3). Allow the oil to drain into a

suitable container.

3. Remove oil filler plug (2) in order to vent the final

drive as the oil drains out of the final drive.
SEBU7764-10 157
Maintenance Section
Final Drive Oil Sample - Obtain

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

Obtain the sample of the differential and final drive oil

as close as possible to the recommended sampling
interval. The recommended sampling interval is every
g00937314 500 service hours. In order to receive the full effect
Illustration 224 of S·O·S oil analysis, you must establish a consistent
trend of data.
1. Position one final drive so that oil level mark (1) is
horizontal with the oil filler plug (2).

2. Remove oil filler plug (2).

3. The oil level should be at the bottom of the filler

plug opening. Add oil, if necessary.

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

5. Install oil filler plug (2).

6. Repeat Step 1 to Step 5 in order to check the oil

level in the other final drive.

i01835051

Final Drive Oil Sample - Obtain

SMCS Code: 3258-008; 4050-008; 7542-008

g00937447
Illustration 225

Hot oil and components can cause personal in- 1. Position one final drive so that oil level mark (1) is
jury. horizontal. Drain plug (3) should face downward.

Do not allow hot oil or components to contact 2. Remove oil filler plug (2) and obtain the oil sample
skin. with a proper suction device.

3. Install oil filler plug (2).

4. Repeat Step 1 through Step 3 in order to sample

the oil in the other final drive.
158 SEBU7764-10
Maintenance Section
Final Drive Seal Guard - Inspect/Clean

i02211034 i02782443

Final Drive Seal Guard - Final Drive Seal Guard Packing

Inspect/Clean - Replace
(If Equipped) (If Equipped)
SMCS Code: 4052-040; 4052-070 SMCS Code: 4052-510

Note: The final drive seal guards may need to be The design of the seal guard has a packing that
inspected more frequently than the standard 500 prevents debris from entering the area of the
service hour interval when the machine is operated Duo-Cone Seal Gp. The close fit and tolerances limit
in very severe applications. Adjust the interval, if the size of the debris that can enter the labyrinth seal
necessary. to 2 mm (0.079 inch). The labyrinth seal changes
the direction of the debris four times. Contact may
be made at the packing after the fourth time. The
packing material is impregnated with silicone oil.
Therefore, it is not necessary to fill the cavity for the
packing with grease. The packing is held in place
by retainers that can be removed. This allows the
replacement of the packing without removing the final
drive. The packing has a split that allows the packing
to be placed over the spindle.

Replacement of the Packing

g00941487
Illustration 226
(1) Guard
(2) Inspection cover

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

2. Inspect the condition of the final drive underneath

the guard. Inspect the final drive for debris or
abrasive substances that are wrapped around the
final drive such as cable or wire.

3. If the area inside the guard is packed with debris g00939700

Illustration 227
or abrasive substances, remove guard (1) and
clean the debris or abrasive substances from the (4) Bolt
(5) Washer
guard and the final drive. (6) Retainer

4. Install the guard (1) onto the final drive. 1. Remove bolts (4) and washers (5). Remove
retainers (6).
5. Install the inspection cover (2) on the guard (1).

Reference: Refer to Operation and Maintenance

Manual, “Final Drive Seal Guard Packing - Replace
(If Equipped)” for more information on the procedure
to replace the packing.
SEBU7764-10 159
Maintenance Section
Final Drive Seal Guard Packing - Replace

g01387828
Illustration 228
Cross section view of seal guard
(3) Seal guard
(6) Retainer
(7) Inner packing
(9) Outer packing
(D) 2 mm (0.079 inch)
g00941695
Illustration 229
2. Inspect the packing and the seal guard for (7) Inner packing
evidence of leaking through the packing. Remove (8) Joint in the inner packing
packing (7) and (9) from seal guard (3). Oil (A) Diameter (A)
leakage through the packing would indicate
leakage of the Duo-Cone Seal Gp in the final 3. Install inner packing (7). Place a thin film of
drive. Inspect the Final Drive for oil leakage 129-1928 Grease on diameter (A). Stretch the
through the Duo-Cone Seal Gp. If oil is leaking packing during installation. Smooth the packing
through the seal, replace the Duo-Cone Seal and keep the packing uniform. Minimize the joint
Gp. Refer to the Service Manual. (8) at the ends of the inner packing (7).

Table 22
Required Parts
Part Number Qty Description
189-6244 2 Seal (packing)
129-1928 1 Grease

Note: Each final drive seal guard requires two

189-6244 Seals (packing). The sections of packing
are installed on top of each other in the groove of
the seal guard.
160 SEBU7764-10
Maintenance Section
Final Drive Seal Guard Packing - Replace

g00939660
Illustration 231
(4) Bolt
(5) Washer
(6) Retainer
(9) Outer packing
(10) Joint in outer packing
(11) Joint in retainers
g00940433 (C) 90 Degrees from joint in outer packing to joint in retainers
Illustration 230
(9) Outer packing Note: The joint (10) in the outer packing (9) must be
(10) Joint in the outer packing
(A) Diameter (A) offset 90 degrees (C) to the joints (11) in the retainers
(B) 180 degrees (6).

4. Install the outer packing (9). Offset the joint in 5. Assemble retainers (6) to seal guard (3) with
the inner packing (8) and the outer packing washers (4) and bolts (5). The clearance at area
(10) at 180 degrees. Stretch the packing during (D) should be 2 mm (0.079 inch).
installation. Smooth the packing and keep the
packing uniform. Minimize the joint (10) at the 6. Repeat steps 3 through 5 in order to replace the
ends of the outer packing (9). packing on the other final drive, if necessary.

7. Replace the final drive seal guards.

Reference: Refer to Operation and Maintenance

Manual, “Final Drive Seal Guard - Inspect/Clean (If
Equipped)” for the correct procedure for installing
the final drive seal guards.
SEBU7764-10 161
Maintenance Section
Fuel Lines - Replace

i03897733

Fuel Lines - Replace

(Low Pressure)
SMCS Code: 1274

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

Replace Nonmetallic Fuel Lines

Make sure to replace the nonmetallic fuel lines
at the engine overhaul.
162 SEBU7764-10
Maintenance Section
Fuel Lines - Replace

g02141035
Illustration 232
Top view of engine

2. Remove and install the front two low-pressure fuel

NOTICE lines (2) with new hoses.
Keep all parts clean from contaminants.
Reference: Refer to the Engine Disassembly
Contaminants may cause rapid wear and shortened and Assembly for information on removing and
component life. installing the fuel lines.

Note: Make sure that the hoses do not contact

1. Remove and install the rear two low-pressure fuel nearby components. Contact with other surfaces will
lines (1) with new hoses. produce chafing that could lead to a leak. A properly
installed hose will contact only the hose clips.
SEBU7764-10 163
Maintenance Section
Fuel System - Prime

i02440374

Fuel System - Prime

SMCS Code: 1258

If the engine does not start, air may be trapped in the

fuel lines to the engine. Use the following procedure
in order to purge air from the fuel lines.

Electric Fuel Priming Pump

NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
g01047632
nected fuel system component. Illustration 234

3. Move the switch for the electric fuel priming pump

1. Turn the ignition switch to the “OFF” position. to the ON position. Allow the fuel priming pump to
run for several seconds.

4. Return the switch for the fuel priming pump to the

OFF position.

NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.

5. Start the engine. If you cannot start the engine,

the engine needs more priming. If the engine
continues to misfire or to smoke, more priming is
g01133444
necessary.
Illustration 233
Note: The electric fuel priming pump will only operate
2. Open the access door on the left side of the cab. if the engine start switch key is in the OFF position.
Shut off the engine before any additional priming.

6. Run the engine at the LOW IDLE position until the

engine runs smoothly.

7. Close the access door.

Note: Do not activate the priming pump while you

crank the engine.
164 SEBU7764-10
Maintenance Section
Fuel System Primary Filter - Clean/Replace

i02031921

Fuel System Primary Filter -

Clean/Replace
SMCS Code: 1260-070-PY; 1260-510-PY

Personal injury can result from air pressure.

Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

g01047193
Illustration 235
Personal injury can result when using cleaner sol-
vents.
Close the fuel shutoff valve (5).
To help prevent personal injury, follow the instruc-
tions and warnings on the cleaner solvent contain- 1. Place drain hose (4) on the outside of the machine.
er before using.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
Personal injury or death can result from a fire. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
Fuel leaked or spilled onto hot surfaces or electri- nent containing fluids.
cal components can cause a fire.
Refer to Special Publication, NENG2500, “Caterpillar
Clean up all leaked or spilled fuel. Do not smoke Tools and Shop Products Guide” for tools and supplies
while working on the fuel system. suitable to collect and contain fluids on Caterpillar
products.
Turn the disconnect switch OFF or disconnect the
battery when changing fuel filters. Dispose of all fluids according to local regulations and
mandates.
NOTICE
Do not fill fuel filters with fuel before installing them. 2. Open drain valve (3) under water separator bowl
Contaminated fuel will cause accelerated wear to fuel (2). The water separator bowl is under the primary
system parts. fuel filter.

3. Remove primary filter element (1) and water

separator bowl (2). Make sure that all of the old
filter seals are removed from the filter base.

4. Remove the water separator bowl from the

primary filter element.

5. Wash the water separator bowl in a clean

nonflammable solvent. Use pressure air to dry the
water separator bowl.
SEBU7764-10 165
Maintenance Section
Fuel System Secondary Filter - Replace

6. Install clean water separator bowl (2) onto a new

primary filter element (1). Only hand tighten the
water separator bowl. When the seal contacts
Personal injury or death can result from a fire.
the base, tighten the water separator bowl for
an additional 1/4 turn.
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire.
7. Clean the filter base.
Clean up all leaked or spilled fuel. Do not smoke
8. Coat the seal of the new primary filter element
while working on the fuel system.
with clean diesel fuel.
Turn the disconnect switch OFF or disconnect the
9. Install primary filter element (1) onto the filter. Only
battery when changing fuel filters.
hand tighten the primary filter element. When the
seal contacts the base, tighten the primary
filter element for an additional 1/3 to 1/2 turn. NOTICE
Do not fill fuel filters with fuel before installing them.
10. Place drain hose (4) in position. Contaminated fuel will cause accelerated wear to fuel
system parts.
11. Close drain valve (3).

12. Open the fuel shutoff valve. Note: Before you replace the secondary fuel filter
element, replace the primary fuel filter element.
i02437924

Fuel System Secondary Filter -

Replace
SMCS Code: 1261-510-SE

Personal injury can result from air pressure.

Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing. g01047225
Illustration 236

Maximum air pressure at the nozzle must be less RJG1-528

than 205 kPa (30 psi) for cleaning purposes.
The secondary fuel filter is located behind the access
door on the left side of the machine.

Personal injury can result when using cleaner sol-

vents.

To help prevent personal injury, follow the instruc-

tions and warnings on the cleaner solvent contain-
er before using.
166 SEBU7764-10
Maintenance Section
Fuel Tank Cap Filter and Strainer - Replace/Clean

4. Coat the seal of the new filter element with clean

diesel fuel.

5. Install the new filter element by hand. When the

seal contacts the base, tighten the secondary
filter element for an additional 1/3 to 1/2 turn.

Rotation index marks are positioned on the filter

element at 90 degree intervals. Use these rotation
index marks as a guide when you tighten the filter.

6. Open the fuel shutoff valve.

7. Prime the fuel system.

i01969542

Fuel Tank Cap Filter and

Strainer - Replace/Clean
Illustration 237
g01218164 SMCS Code: 1273-070-STR; 1273-070-Z2
RJG529-Up

The secondary fuel filter is located behind the access

door on the right side of the machine.

g01022482
Illustration 239

The fuel tank is located on the rear of the machine.

The filler cap (1) is on the left side of the machine
next to the ROPS.

Only vented fuel caps have filters. Machines without

the fast fill fuel adapter require a vented fuel cap.

g01046499
Illustration 238
Primary fuel filter and fuel shutoff valve

1. Close the fuel shutoff valve. The fuel shutoff valve

is located on the front left side of the fuel tank.

2. Remove the filter element. Discard the filter

element properly.

3. Clean the filter housing base. Make sure that all of

the old seal is removed.
g01110732
Illustration 240
SEBU7764-10 167
Maintenance Section
Fuel Tank Water and Sediment - Drain

1. Lift lever (5) in order to remove the fuel tank filler

cap. Turn the lever counterclockwise until the
lever stops. Lift the cap straight up in order to
remove the cap.

2. Remove the fuel strainer from the filler neck.

3. In order to replace the filter assembly, remove two

screws that secure filter assembly (4) to the fuel
cap. Remove filter assembly (4), valve (3), and
the gaskets.

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

nonflammable solvent.
g01390659
5. Inspect the tank cap seal. If the seal is damaged, Illustration 241
replace the seal. Rear view

6. Replace the filter assembly, the valve, the gaskets, The drain valve is under the fuel tank at the rear of
and the screws. Use a 9X-2205 Cap Filter Kit. the machine.

7. Install the strainer. 1. Open drain valve (1) under the left side of fuel
tank (2). (Unlock the drain valve, as needed.)
8. Install the fuel cap. Rotate the fuel cap clockwise Allow the water and the sediment to drain into a
until three tabs (7) drop into the slots in the suitable container.
adapter. Rotate lever (5) clockwise until the lever
stops. Lower lever (5) over locking tab (6). 2. Close the drain valve. Lock the drain valve, if
necessary.
Fast Fill Fuel Adapter (If Equipped)
i02606340
See illustration 239.
Fuses and Circuit Breakers -
Machines that are equipped with a fast fill fuel adapter
(2) have identical fuel caps as systems without a
Replace/Reset
fast fill fuel adapter. Use the same procedure for SMCS Code: 1417-510; 1420
changing the filter in the two systems.
Fuses – Fuses protect the electrical
i02784163 system from damage that is caused by
overloaded electrical circuits. Replace
Fuel Tank Water and Sediment a fuse if the element separates. If the fuse of
a particular electrical system requires frequent
- Drain replacement, check the electrical circuit. Repair the
electrical circuit, if necessary.
SMCS Code: 1273-543-M&S

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and Illustration 242

g01053625
mandates.
168 SEBU7764-10
Maintenance Section
High Intensity Discharge Lamp (HID) - Replace

The access cover for the fuses and the circuit Ignition Key (13) – 10 Amp
breakers is located inside the cab on the left side of
the seat. Fender Floodlights (14) – 15 Amp

Open the cover for access to the circuit breakers Horn (15) – 15 Amp
and the fuses.
CAES Display (16) – 10 Amp
NOTICE
Always replace fuses with the same type and capacity Secondary Brake (17) – 15 Amp
fuse that was removed. Otherwise, electrical damage
could result. Unswitched Auxiliary (18) – 15 Amp

Product Link (19) – 15 Amp

NOTICE
If it is necessary to replace fuses frequently, an elec- Advisor Panel (20) – 15 Amp
trical problem may exist.
Implement ECM (21) – 15 Amp
Contact your Caterpillar dealer.
Implement ECM (22) – 15 Amp

Engine ECM (23) – 20 Amp

24 VA − 12 VA Converter (24) (Attachment) – 20

Amp

Cover (25) – Fuse panel

Fuse (26) – 175 Amp

Fuse cover(27) – Plastic

Power outlet(28) – 12 Volt

Illustration 243
g01106464 Starting/Charging Analyzer (29) (Plug) – 70-pin
(A) Open fuse box
Connector
(B) Open fuse panel
HVAC blower (30) (Reset button) – 15 Amp
ROPS floodlights(1) – 15 Amp
Fuse Puller (31) – Auto Stop
Ripper floodlights (2) (Cylinder) – 15 Amp
Remote Air Conditioner Condenser (32) – 15 Amp
ECM engine monitoring (3) (Power train ECM) –
15 Amp i02245859

Rear ROPS floodlights (4) – 15 Amp High Intensity Discharge Lamp

Auxiliary (5) – 10 Amp (HID) - Replace
(If Equipped)
Spare (6) – 20 Amp
SMCS Code: 1434-510
GPS/Radio Transmission Antenna (7) – 15 Amp

Seat, Ripper, or Implements (8) – 15 Amp

Standard Converter (9) – 10 Amp HID lamps operate at very high voltages. To avoid
electrical shock and personal injury, disconnect
Spare (10) – 15 Amp power before servicing HID lamps.

“Accugrade” (11) – 15 Amp

Wipers (12) – 15 Amp

SEBU7764-10 169
Maintenance Section
Horn - Test

i02054663

Horn - Test
HID bulbs become very hot during operation.
Before servicing, remove power from lamp for at SMCS Code: 7402-081
least five minutes to ensure lamp is cool.
Test the horn on a daily basis. Press downward on
the horn button in order to sound the horn. If the horn
NOTICE
does not sound, make the necessary repairs before
Although HID bulb materials may change over time,
you operate the machine.
HID bulbs produced at the time of the printing of this
manual contain mercury. When disposing of this com-
ponent, or any waste that contains mercury, please i03898104
use caution and comply with any applicable laws.
Hoses and Clamps -
1. Remove the electrical power from the high Inspect/Replace
intensity discharge lamp (HID). The electrical
power must be removed from the HID lamp for SMCS Code: 7554-040; 7554-510
at least five minutes, in order to ensure that the
bulb is cool. Inspect the Hoses and the Clamps
2. Disassemble the housing for the HID lamp in order The nonmetallic hoses and the clamps must be
to have access to the bulb. inspected periodically in order to ensure safe
operation and continuous operation of the engine
Note: On some HID lamps, the bulb is an integral fuel system. Take proper safety precautions before
part of the lens assembly. The bulb is not removed inspecting or replacing hoses and clamps.
separately from the lens assembly. Replace the
entire lens assembly on these HID lamps. Note: Always use a board or cardboard when the
engine components are checked for leaks. Leaking
3. Remove the bulb from the HID lamp. fluid that is under pressure can cause serious injury
or possible death. This proceeding includes leaks
4. Install the replacement bulb in the HID lamp. that are the size of a pin hole. Refer to Operation and
Maintenance Manual, “General Hazard Information”
If the bulb is an integral part of the lens assembly, for more information.
install the replacement lens assembly in the HID
lamp.
Nonmetallic Fuel Lines
Note: In order to avoid failure to the bulb that is
Note: Make sure that the hoses do not contact
premature, avoid touching the bulb's surface with
nearby components. Contact with other surfaces will
your bare hands. Clean any fingerprints from the bulb
produce chafing that could lead to a leak. A properly
with alcohol prior to operation.
installed hose will contact only the hose clips.
5. Reassemble the housing for the HID lamp. Ensure
that any printing on the lens is oriented correctly
with respect to the HID lamp's mounting position
on the machine.

6. Reattach the electrical power to the HID lamp.

7. Check the HID lamp for proper operation.

Note: Consult your Caterpillar dealer for additional

information on HID lamps.
170 SEBU7764-10
Maintenance Section
Hoses and Clamps - Inspect/Replace

g02141367
Illustration 244
(1) Rear low-pressure fuel lines (2) Front low-pressure fuel lines

Inspect hoses (1, 2) of the engine fuel system for the • Outer covering that is ballooning locally
following conditions.
• Flexible part of the hose that is kinked or crushed
Replace any hose which exhibits any of the following
conditions. • Hoses which exhibit signs of leakage which are not
the result of loose couplings or clamps
• Hoses which are cracked
Inspect all hose couplings for leaks. Replace any
• Hoses which are soft hose that exhibits signs of coupling leakage.

• Outer covering that is chafed or cut

SEBU7764-10 171
Maintenance Section
Hydraulic System Filter Bypass Screen - Clean

Inspect all clamps for the following conditions. 2. Turn the engine start switch key to ON.
Replace any parts that exhibit signs of any of the
following conditions. 3. Move the hydraulic control levers through all of
the positions in order to release pressure.
• Missing or damaged grommets
4. Turn the engine start switch key to OFF.
• Missing fasteners
• Missing clamps
Failure to replace a non-metallic fuel line (hose) At operating temperature, the hydraulic tank is hot
which exhibits any of the above conditions may result and under pressure.
in a leak.
Hot oil and components can cause personal in-
jury. Do not allow hot oil or components to contact
Replace the Hoses and the Clamps skin.

NOTICE Before removing the filler cap, press the valve re-
Care must be taken to ensure that fluids are contained lief button on the hydraulic tank in order to relieve
during performance of inspection, maintenance, test- the tank pressure.
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- Remove the filler cap only when the engine is
ing any compartment or disassembling any compo- stopped and the filler cap is cool enough to touch
nent containing fluids. with your bare hand. Remove the filler cap slowly
in order to relieve any remaining pressure.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Pub-
lication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and

mandates.

Reference: Refer to the Engine Disassembly and

Assembly for information on removing and installing
the low-pressure fuel lines.

i03624384
g01944042
Illustration 245
Hydraulic System Filter Front view of the hydraulic tank
Bypass Screen - Clean (1) Filler Cap
(2) Breaker Relief Valve
(3) Sight Glass
SMCS Code: 5068-070 (4) Drain Valve

The screen should be cleaned especially when one 5. Press the button on the breaker relief valve (2) in
of the following situations have occurred: order to relieve any tank pressure. Slowly remove
filler cap (1).
• Failure of the Implement Pump
• Failure of the Fan Pump
• Failure of the Fan Motor
• Cleaning of the Hydraulic Tank
• PCR (Engine Overhaul)
1. Park the machine on a level surface. Lower the
work tool to the ground. Engage the parking brake.
172 SEBU7764-10
Maintenance Section
Hydraulic System Filter Bypass Screen - Clean

g01944045 g01944047
Illustration 246 Illustration 248
Bottom view of the Hydraulic Tank Return screens
(5) Suction for Fan Drive Pump (A) Implement return
(6) Suction for Implement Pump (B) Case drain return
(7) Hydraulic tank access cover (C) Fan return
(8) Implement return port
(9) Case drain return
(10) Fan return
9. Remove return screens that are within reach. It
may be necessary to remove the filter from the
top to reach one return screen. Clean the screens
6. Drain the hydraulic oil tank at drain (4).
with a clean, nonflammable solvent.
Reference: For the correct procedure, refer to
10. Inspect the O-ring seal, if the casting is removed.
Operation and Maintenance Manual, “Hydraulic
System Oil - Change”. If the seal is damaged, replace the seal.

11. Replace the return screens.

7. Disconnect the drain lines.
12. Replace hydraulic tank access cover (7).
8. Unbolt hydraulic tank access cover (7).
13. Assemble the drain lines.

14. Fill the hydraulic tank.

Reference: For the correct procedure, refer to

Operation and Maintenance Manual, “Hydraulic
System Oil - Change”.

15. Replace filler cap (1).

g01944044
Illustration 247
Top view of the Hydraulic Tank
SEBU7764-10 173
Maintenance Section
Hydraulic System Oil - Change

i02187439

Hydraulic System Oil - Change

SMCS Code: 5050-044

Note: The normal hydraulic oil change interval

is at every 2000 Service Hours or 1 Year. By
performing S·O·S oil analysis, the hydraulic
oil change interval may be extended to 4000
Service Hours or 2 Years. S·O·S oil analysis
must be performed at every 500 Service Hours
or 3 Months in order to extend the hydraulic oil
change interval. The results from the S·O·S oil
analysis will determine if the hydraulic oil change
g01053702
interval may be extended. If S·O·S oil analysis is Illustration 249
not available, the hydraulic oil change interval
must remain at every 2000 Service Hours or 1 1. Remove the pressure in the hydraulic tank. Press
Year . Refer to the Operation and Maintenance the stem in the center of the valve (1).
Manual, “Hydraulic System Oil Sample - Obtain”.
2. Remove the hydraulic tank filler cap (2) slowly in
order to prevent the rapid escape of oil or air.

3. Clean the filler strainer and the filler cap in a clean

At operating temperature, the hydraulic tank is hot nonflammable solvent.
and under pressure.
4. Remove the oil drain plug (4).
Hot oil and components can cause personal in-
jury. Do not allow hot oil or components to contact 5. Attach a hose to a swivel. Install the swivel and the
skin. hose into the drain plug opening. A pipe nipple and
a hose can also be used. Do not tighten the pipe.
Remove the filler cap only when the engine is
stopped, and the filler cap is cool enough to touch 6. Use a 8 mm wrench or a adjustable wrench to
with your bare hand. Remove the filler cap slowly open the drain valve. Allow the oil to drain into a
in order to relieve pressure. suitable container.

NOTICE Note: If there is a failure the hydraulic tank and the

Care must be taken to ensure that fluids are contained hydraulic screen must be cleaned. Refer to Operation
during performance of inspection, maintenance, test- and Maintenance Manual, “Hydraulic System Return
ing, adjusting and repair of the machine. Be prepared Screen-Clean” for the procedure.
to collect the fluid with suitable containers before
opening any compartment or disassembling any com- 7. Remove the swivel. The valve for the hydraulic
ponent containing fluids. tank will close.

Refer to Special Publication, NENG2500, “Caterpillar 8. Clean the drain plug and install the drain plug.
Tools and Shop Products Guide”, for tools and sup- Tighten the drain plug to a torque of 68 ± 7 N·m
plies suitable to collect and contain fluids. (50 ± 5 lb ft). Install the oil drain plug cover.

Dispose of all fluids according to local regulations and 9. Change the hydraulic system filter. See Operation
mandates. and Maintenance Manual, “Hydraulic System Oil
Filter - Replace”.

Operate the machine in order to warm the oil. Park 10. Install the filler strainer.
the machine on level ground. Lower the blade to the
ground and apply slight downward pressure. Engage 11. Fill the hydraulic oil tank. See Operation and
the parking brake and stop the engine. Maintenance Manual, “Refill Capacities” in order
to determine the amount of hydraulic oil that is
The hydraulic tank is located on the right side of the needed to fill the hydraulic oil tank.
cab.
12. Inspect the filler cap gasket. Replace the gasket if
damage or wear is evident.
174 SEBU7764-10
Maintenance Section
Hydraulic System Oil Filter (Pilot) - Replace

13. Install the filler cap.

14. Start the engine. Run the engine for a few

minutes.

15. Maintain the oil level to the “FULL” mark in the

sight gauge (3). Add oil, if necessary.

16. Stop the engine.

i02055215

Hydraulic System Oil Filter

(Pilot) - Replace g01060020
Illustration 251
SMCS Code: 5068-510; 5068-510-PS; 5092-510
1. Remove the filter element (2). Dispose of the used
filter element properly.
NOTICE
Care must be taken to ensure that fluids are contained
2. Install a new filter element.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
3. Start the machine. Allow the hydraulic oil to warm.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
4. Check the machine for leaks. Repair any leaks, if
nent containing fluids.
necessary.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies i02277262
suitable to collect and contain fluids on Caterpillar
products. Hydraulic System Oil Filters -
Dispose of all fluids according to local regulations and
Replace
mandates. SMCS Code: 5068-510

At operating temperature, the hydraulic tank is hot

and under pressure.

Hot oil and components can cause personal in-

jury. Do not allow hot oil or components to contact
skin.

Remove the filler cap only when the engine is

stopped, and the filler cap is cool enough to touch
with your bare hand. Remove the filler cap slowly
in order to relieve pressure.
g01059883
Illustration 250

The pilot oil filter is located inside the access panel

(1) on the right side of the machine.
SEBU7764-10 175
Maintenance Section
Hydraulic System Oil Filters - Replace

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the machine. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide”, for tools and sup-
plies suitable to collect and contain fluids.

Dispose of all fluids according to local regulations and

mandates.

Note: The hydraulic tank is equipped with two filter

elements. The hydraulic tank is located on the right
side of the cab.

1. Lower the bulldozer and the ripper to the ground. g01053837

Illustration 253

4. Remove the rods (7) and (9) that retain the filter
elements. Unscrew the nuts that are located at
the bottom of the rods. Remove the filter elements
(6) and (8) by sliding the filters off rods (7) and
(9). Properly discard the filter elements. Install
new filter elements. Screw the nuts onto the rods
and tighten the nuts to a torque of 10 ± 1.5 N·m
(7.4 ± 1.1 lb ft).

5. Place filters back into the hydraulic tank.

6. Wash the covers in a clean nonflammable solvent.

Illustration 252
g01053825 7. Install the seals and the covers.

2. Check the pressure in the hydraulic tank. Press 8. Maintain the hydraulic oil to the “FULL” mark in
the stem in the center of the valve (1) in order to the sight gauge (5).
relieve the system pressure.

3. Remove the nuts from the covers (2) and (3).

Rotate the covers counterclockwise in order to
remove the covers. Remove the cover seals.
Replace the cover seals if the seals are damaged.
176 SEBU7764-10
Maintenance Section
Hydraulic System Oil Level - Check

i02195781 i02054835

Hydraulic System Oil Level - Hydraulic System Oil Sample

Check - Obtain
SMCS Code: 5056-535-FLV; 7479 SMCS Code: 5050-008; 7542-008

At operating temperature, the hydraulic tank is hot Hot oil and components can cause personal in-
and under pressure. jury.

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

Remove the filler cap only when the engine is NOTICE

stopped, and the filler cap is cool enough to touch Care must be taken to ensure that fluids are contained
with your bare hand. Remove the filler cap slowly during performance of inspection, maintenance, test-
in order to relieve pressure. ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
Lower the bulldozer and the ripper to the ground. nent containing fluids.
The hydraulic tank is on the right side of the cab. Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

Obtain the hydraulic oil sample as close as possible

to the recommended sampling interval. The
recommended sampling interval is every 500 service
hours. In order to receive the full effect of S·O·S oil
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
Illustration 254
g01053736 spaced.

1. Maintain the oil level to the “FULL” mark in the

sight gauge (3). Put the tilt cylinders in the center
position before you check the oil level. Check the
oil level when the oil is cold. Verify that the oil
level is below the “FULL” mark before you remove
the filler cap.

If the hydraulic system requires additional hydraulic

oil, perform the following procedure.

1. Check for pressure in the hydraulic tank. Press

the stem in the center of the valve (1).

2. Use caution to remove filler cap (2). Slowly remove g01053745

Illustration 255
the filler cap and add oil through the filler tube.

3. Clean the filler cap and install the filler cap. 1. Remove the protective cap from the sampling
valve (1).
SEBU7764-10 177
Maintenance Section
Indicators and Gauges - Test

2. Use 169-8373 Fluid Sampling Bottle in order to The operator must observe the indicators and
obtain the sample. the gauges in order to determine whether gauge
modules, the action light, the alert indicators, and the
3. After you take a sample, remove the cap with display screen are operating properly. The self test
the tube and the probe from the bottle. Discard lasts for approximately three seconds.
the cap with the tube and the probe. Install the
sealing cap that is provided with 169-8373 Fluid During the self test, all alert indicators flash.
Sampling Bottle.
The digital display shows the following readouts:
4. Replace the protective cap.
• All indicators of units (Deg C, kPa, rpm, and liters)
Refer to Operation and Maintenance Manual,
“Lubricant Viscosities” for the correct fluid for your • “X100” readout
machine.
• Symbol for the hour meter
i02184397
• “8.8.8.X.8.8” readout
Indicators and Gauges - Test The pointers in the gauges point upward. Then, the
SMCS Code: 7450-081 pointers point to the left. Then, the pointers point
to the right. Then, the pointers point to the final
positions.

• The speed readout shows “188”, “MPH”, and

If the action alarm does not sound during this test “km/h”.
or machine monitoring displays are not function-
ing, do not operate the machine until the cause • The action light stays illuminated.
has been corrected. Machine operation with faulty
action alarms or displays could result in injury or • The action alarm sounds once.
death as any Warning Category 3 notifications will
not be relayed to the operator. The monitoring panel is then in the normal operating
mode.
Check the operation of the Monitoring System.
Observe the self test when you start the engine. If the above tests are not correctly completed, the
system will not function in the normal operating
The system performs an automatic self test when mode. Consult your Caterpillar dealer for an electrical
you turn the engine start switch to the ON position. system check. Any repairs must be made before you
start the engine.
The self test verifies that the monitoring panel and
the display modules are operating properly. Turn on all of the machine lights. Check for proper
operation. Sound the forward horn.
The internal circuits, the indicators, and the gauges
are automatically checked. Stop the engine.

Make any necessary repairs before you operate the

machine.

i03600040

Ladder - Adjust
SMCS Code: 0634-025; 7254-025

Adjust the Access Ladder

g01106466
Illustration 256 Do not ride on ladder or stand on platform while
machine is moving.
178 SEBU7764-10
Maintenance Section
Ladder Hinge Oil - Change

5. Install the oil level/fill plug. Inspect the hinge block

NOTICE for leaks. Repair any visible leaks.
To avoid damage to the ladder during machine oper-
ation, keep the ladder in the LATCHED position. 6. Start the engine. See “Starting Engine”.

1. Position adjustment for the hinge. i02055282

a. Adjust the hinge so that the ladder is parallel to Lift Cylinder Yoke Bearings -
the top surface of the fender with the ladder in Lubricate
the UP position.
SMCS Code: 5102-086-BD
2. Adjustment for the location of the latch

a. The latch should be adjusted so that the pins

for the latch are equally engaged in the top and
the bottom of the ladder.

3. Adjustment for the contact plates on the latch

a. The contact plates on the latch should be

adjusted in order to prevent any vertical
movement or any side to side movement of the
ladder when the latch pins are engaged in the
ladder.

4. Adjustment for the location of the proximity switch

g01053980
Illustration 257
a. With the ladder in the Up position, adjust the (1) Lift cylinder yoke
proximity switch so that the switch and the
magnet are aligned. The fittings are on the left front side of the machine
and on the right front side of the machine. Lubricate
b. There must be a gap between the magnet the bearings by applying MPGM grease to the fittings.
and the switch in order to prevent contact
when the ladder moves. The gap between the
magnet and the switch must be close enough i02106227

to function correctly. Oil Filter - Inspect

i03996530 SMCS Code: 1318-507; 3067-507; 5068-507

Ladder Hinge Oil - Change Inspect a Used Filter for Debris

SMCS Code: 0634-510-OC; 7254-510-OC

Change the Oil

1. Park the machine.

2. Clean the areas on the hinge block that are near

the oil level/fill plug and near the drain plug.

3. Remove the drain plug from the hinge block. Drain

the oil completely into a suitable container.

Note: Inspect the oil for particles. Large particles

indicate that a failure has occurred. Consult your Cat
dealer if this issue occurs. g00100013
Illustration 258
The element is shown with debris.
4. Install the drain plug. Fill the hinge block with
“FDA060” oil to the bottom of the oil level/fill plug.
SEBU7764-10 179
Maintenance Section
Power Train Breather - Clean

Use a filter cutter to cut the filter element open.

Spread apart the pleats and inspect the element for
metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
failure.

If metals are found in the filter element, a magnet can

be used to differentiate between ferrous metals and
nonferrous metals.

Ferrous metals can indicate wear on steel parts 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. Illustration 260
g01219168

Using an oil filter element that is not recommended 2. Remove the breather. Clean the breather in a
by Caterpillar can result in severe engine damage clean, nonflammable solvent. Allow the breather
to engine bearings, to the crankshaft, and to other to air dry.
parts. This can result in larger particles in unfiltered
oil. The particles could enter the lubricating system 3. If the transmission breather is damaged or if the
and the particles could cause damage. breather is not reusable, discard the used breather
element. Install a new breather element.
i03996833
4. Install the transmission breather.
Power Train Breather - Clean
Alternate Location
SMCS Code: 3030-070-BRE
Some later machines will have an alternate location
for the power train breather. This location is inside
the enclosure above the left fender.

g01133444
Illustration 259

1. Open the access door on the left side of the cab.

g02174560
Illustration 261
180 SEBU7764-10
Maintenance Section
Power Train Oil Filters - Replace

Open the access door to the left side enclosure,

as shown. Unscrew and remove the transmission
breather.

1. Perform steps 2 to 4

i03652871

Power Train Oil Filters -

Replace
SMCS Code: 3067-510

Hot oil and components can cause personal in-

jury.

Do not allow hot oil or components to contact

skin.
g00610821
Illustration 262
Rear view of machine
NOTICE
Care must be taken to ensure that fluids are contained 2. Remove the lock pin bolt, secondary bar pin and
during performance of inspection, maintenance, test- washer (1) from the bracket.
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- 3. Lift transmission guard (3) from the bottom of the
ing any compartment or disassembling any compo- guard. Lift the transmission guard until the end of
nent containing fluids. handle (2) extends beyond the fender to position
(C). This locks the guard in the OPEN position.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar Replace the Transmission and
products. Torque Converter Oil Filters
Dispose of all fluids according to local regulations and
mandates.

The transmission and torque converter oil filters are

under the fuel tank on the rear of the machine.

Lifting the Transmission Guard (if

equipped)
1. If the machine is equipped with a transmission
guard, support the transmission guard with the
proper lifting device.
g01050289
Illustration 263
Transmission oil filter 4
Torque converter oil filter 5

Note: The Caterpillar recommended filters are

a special high efficiency design. Use only the
recommended filter.
SEBU7764-10 181
Maintenance Section
Power Train Oil - Change

i03965831
NOTICE
The element in the transmission oil filter can become
Power Train Oil - Change
plugged with debris.
SMCS Code: 4000-044-OC
The flow of clean oil to the system will decrease or
stop.

Follow maintenance recommendations to ensure ele- Hot oil and components can cause personal in-
ment will not fill up with debris. jury.

Do not allow hot oil or components to contact

NOTICE skin.
Dirty oil or debris left in the transmission filter housing
during filter change can enter the transmission and
cause serious damage. NOTICE
Care must be taken to ensure that fluids are contained
Use a clean, dry cloth to clean the bottom of the hous- during performance of inspection, maintenance, test-
ing. ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
1. Remove the filter element housing for the nent containing fluids.
transmission oil filter (4) and the torque converter
oil filter (5). Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
2. Remove the filter elements and properly discard suitable to collect and contain fluids on Caterpillar
the filter elements. products.
3. Clean the inside of the filter element housings Dispose of all fluids according to local regulations and
with a clean, dry cloth. mandates.
4. Inspect the seals for the housings. If a seal is
damaged, replace the seal. Operate the machine in order to warm the power
train oil. The machine must be level. Lower the
5. Install the new filter elements. Install the filter attachments with slight down pressure.
element housings.
Engage the parking brake switch. Stop the engine.
a. Torque the filter element housings to 61 ± 7 N·m
(45 ± 5 lb ft).

6. Start the engine.

7. Check the transmission oil level. Refer

to Operation and Maintenance Manual,
“Transmission Oil Level - Check” for details.

Lower the Transmission Guard (if

equipped)
1. To lower transmission guard (3), support the guard
with the proper lifting device. g01229675
Illustration 264
2. Position handle (2) to area (B). High speed oil change (transmission)

3. Lower the transmission guard. Install the 1. Open the left engine compartment. The machine
secondary bar pin, the washer and lock pin bolt may be equipped for a high speed oil change. Use
(1) to the brackets. a 126-7538 Nozzle Assembly. The high speed oil
change removes oil from the sump in the bevel
4. Return handle (2) to position (A). gear case. The high speed oil change does not
remove oil from the torque converter or from the
transmission case.
182 SEBU7764-10
Maintenance Section
Power Train Oil - Change

g01181288 g02161317
Illustration 265 Illustration 267

2. If the machine is not equipped with the high speed 5. Remove the plug from the drain valve in the
oil change system, remove the plug from the transmission. Install a 12.7 mm (.50 inch) pipe into
drain in the bevel gear case. Install a 4C-8563 the transmission valve. Use a 12.7 mm (.50 inch)
Swivel into the valve. Clamp a hose to the swivel. pipe with 1/2-14 NPTF threads.
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 6. Clamp a hose to the pipe in order to drain the oil
threads. Do not tighten the pipe. into a suitable container.

3. Turn the swivel or pipe clockwise in order to open 7. Open the drain valve and drain the oil into a
the internal drain valve. Allow the oil to drain into a suitable container.
suitable container.
8. Close the drain valve in the transmission case.

9. Remove the hoses and remove the pipes from

the drains.

10. Remove the swivel or remove the pipe from the

drain in the bevel gear case. The drain valve will
close.

11. Clean the oil drain plugs and install the oil drain
plugs.

12. Change the filter element. See Operation and

Maintenance Manual, “Power Train Oil Filter -
g01181367 Replace”.
Illustration 266

4. Remove the access cover for the transmission

drain plug.

g01307684
Illustration 268

13. Open the left engine compartment for the

transmission oil filler cap.
SEBU7764-10 183
Maintenance Section
Power Train System Oil Level - Check

14. Remove the transmission oil filler cap (2).

15. Add oil. To determine the correct amount of

oil, see Operation and Maintenance Manual,
“Capacities (Refill)”.

16. Clean the transmission oil filler cap and install the
transmission oil filler cap.

g00594099
Illustration 271

HOT TRANSMISSION OIL

Use the “TRANSMISSION IN NEUTRAL, ENGINE
AT LOW IDLE, AND OIL AT OPERATING
TEMPERATURE” side of the dipstick (1). Check
g00611366
when the transmission is in NEUTRAL and the
Illustration 269 engine is running at LOW IDLE. The oil should be at
operating temperature. Maintain the oil level between
17. Maintain the oil level in the “OPR ZONE” on the the “OPERATING ZONE” marks. This is the only
dipstick (1). Close the access door. accurate way to check the oil level.

i03652864
Remove filler plug (2). If necessary, add oil.

Power Train System Oil Level - Clean the filler plug and install the filler plug.
Check
COLD TRANSMISSION OIL
SMCS Code: 3030-535-FLV
Check the “ENGINE STOPPED COLD OIL” side of
dipstick (1) while the engine is stopped. Maintain the
oil between the “OPERATING ZONE” marks. This
method should be used as reference only.
Hot oil and components can cause personal in-
jury. Remove filler plug (2). If necessary, add oil.
Do not allow hot oil or components to contact Clean the filler plug and install the filler plug.
skin.
Note: When you are operating the machine on severe
slopes, the quantity of oil in the transmission can be
increased up to 10 percent. When you are operating
with the increased oil quantity, prolonged operation
in some machines can cause high transmission oil
temperatures. After the work on the severe slopes
has been completed, drain the excessive oil quantity
from the bevel gear case.

g01050163
Illustration 270

Open the access door on the left side of the machine.

184 SEBU7764-10
Maintenance Section
Power Train System Oil Sample - Obtain

i03652868

Power Train System Oil Sample

- Obtain
SMCS Code: 3080-008

Hot oil and components can cause personal in-

jury.

Do not allow hot oil or components to contact

skin.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- g00610800
ing any compartment or disassembling any compo- Illustration 272
nent containing fluids. Transmission guard at the rear of the machine

Refer to Special Publication, NENG2500, “Caterpillar 2. Remove the lock pin bolt, secondary bar pin and
Dealer Service Tool Catalog” for tools and supplies washer (1) from the bracket.
suitable to collect and contain fluids on Caterpillar
products. 3. Lift transmission guard (3) from the bottom of the
guard. Lift the transmission guard until the end of
Dispose of all fluids according to local regulations and handle (2) extends beyond the fender to position
mandates. (C). This locks the guard in the OPEN position.

The transmission oil filter is under the fuel tank on

the rear of the machine.

1. If the machine is equipped with a transmission

guard, support the transmission guard with the
proper lifting device.

g01062228
Illustration 273

4. Remove the protective cap (4) from the sampling

valve.

Note: Flush the fitting with oil into an approved

container before you obtain the oil sample.

5. Use the 8T-9190 Fluid Sampling Bottle in order

to obtain a sample.
SEBU7764-10 185
Maintenance Section
Power Train System Screens - Clean

6. After you take a sample, remove the cap with the Transmission
tube and the probe from the bottle. Discard the
cap with the tube and the probe. Install the sealing
cap that is provided with 8T-9190 Fluid Sampling
Bottle.

7. Replace the protective cap (4) for the sampling

valve.

8. To lower transmission guard (3), support the guard

with the proper lifting device.

9. Position handle (2) to area (B).

10. Lower the transmission guard. Install the lock

pin bolt, secondary bar pin and washer (1) to the
g02161128
brackets. Illustration 274

11. Return handle (2) to position (A). 1. Remove the plug from the drain valve in the
transmission cover (1). Install a 12.7 mm (.50 inch)
pipe with 1/2-14 NPTF threads into the valve.
i03965189
2. Clamp a hose to the pipe in order to drain the oil
Power Train System Screens into a suitable container.
- Clean
3. Open the drain valve and drain the oil into a
SMCS Code: 3067-070 suitable container.

4. Close the drain valve.

5. Remove the hose and remove the pipe from the

Hot oil and components can cause personal in-
drains.
jury.
6. Remove the bolts for the drain cover (2) and
Do not allow hot oil or components to contact
remove the drain cover(3). Remove the seal and
skin.
remove the screen that is located behind the
cover.
NOTICE
Care must be taken to ensure that fluids are contained 7. Wash the screen in a clean, nonflammable
during performance of inspection, maintenance, test- solvent.
ing, adjusting and repair of the machine. Be prepared
to collect the fluid with suitable containers before 8. Inspect the seal. If the seal is damaged, replace
opening any compartment or disassembling any com- the seal.
ponent containing fluids.
9. Install the screen, the seal, and the drain cover on
Refer to Special Publication, NENG2500, “Caterpillar the transmission.
Tools and Shop Products Guide”, for tools and sup-
plies suitable to collect and contain fluids in Caterpillar 10. Clean the oil drain plug and install the oil drain
machines. plug.

Dispose of all fluids according to local regulations and Suction Screen

mandates.
The suction screen for the power train is located
Operate the machine in order to warm the power train below the cab.
oil. The machine must be level. Lower the work tools
with slight down pressure.

When you change the transmission oil, clean the

scavenge screens.
186 SEBU7764-10
Maintenance Section
Pivot Shaft Oil Level - Check

g02161135 g01054187
Illustration 275 Illustration 276

1. Remove the bolts (4) and remove the cover (5). Open the access door on the left side of the cab (1).
Remove the screen that is located behind the
housing.

2. Clean the screen in clean, nonflammable solvent.

3. Install the screen. Install the cover.

4. Refill the transmission with oil. Refer to Operation

and Maintenance Manual, “Power Train Oil Level -
Check” and Operation and Maintenance Manual,
“Capacities - Refill”.

i02927165

Pivot Shaft Oil Level - Check

SMCS Code: 4153-535-FLV

Hot oil and components can cause personal in- g01154544

jury. Illustration 277

Do not allow hot oil or components to contact Maintain the oil within the limits of the dipstick for the
skin. oil reservoir (2). Do not overfill the oil reservoir. Hot
oil can overflow the reservoir.

Note: The initial fill of pivot shaft may trap air in the Remove the oil filler cap in order to add the oil to the
tube. The level of the oil may fall as air escapes. oil reservoir.
Barometric pressure and altitude changes may also
cause the oil level to raise or lower. The reservoir
must be filled several times in order to remain
consistently full.
SEBU7764-10 187
Maintenance Section
Radiator Core - Clean

i02612642

Radiator Core - Clean

SMCS Code: 1353-070; 1805-070; 1810-070

g01048235
Illustration 279

1. Slowly remove the radiator cap in order to relieve

system pressure.
g01307600
Illustration 278 2. Inspect the radiator cap for damage, for deposits,
or for foreign material. Clean the radiator cap
You can use compressed air, high pressure water, with a clean cloth. Replace the radiator cap if the
or steam to remove dust and other debris from the radiator cap is damaged.
radiator core. However, the use of compressed air
is preferred. 3. Install the radiator cap.

See Special Publication, SEBD0518, “Know Your

Cooling System” for the complete procedure for i02055619
cleaning the radiator core.
Recoil Spring Compartment
i02055608
Oil Level - Check
Radiator Pressure Cap - SMCS Code: 4158-535-OC

Clean/Replace
SMCS Code: 1353-070-Z2; 1353-510-Z2
Hot oil and components can cause personal in-
jury.

Do not allow hot oil or components to contact

Pressurized System: Hot coolant can cause seri- skin.
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.

The radiator cap is located inside the access door on

top of the engine enclosure on the left side.

g01054329
Illustration 280

1. Remove all of the debris around the cover plate

(1) on the top of the track roller frame.
188 SEBU7764-10
Maintenance Section
Refrigerant Dryer - Replace

2. Remove the cover plate for the oil filler. The i03642341
dipstick (2) is part of the cover plate.
Refrigerant Dryer - Replace
(If Equipped)
SMCS Code: 7322-510; 7322-535

Personal injury can result from contact with refrig-

erant.

Contact with refrigerant can cause frost bite. Keep

face and hands away to help prevent injury.

Protective goggles must always be worn when re-

Illustration 281
g01054336 frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant.
3. Maintain the oil level above the MIN mark on the
dipstick. Always use precaution when a fitting is removed.
Slowly loosen the fitting. If the system is still un-
4. Install the cover plate. der pressure, release it slowly in a well ventilated
area.
5. Repeat the procedure for the other recoil
compartment. Personal injury or death can result from inhaling
refrigerant through a lit cigarette.

Inhaling air conditioner refrigerant gas through a

lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air con-
ditioner refrigerant gas, can cause bodily harm or
death.

Do not smoke when servicing air conditioners or

wherever refrigerant gas may be present.

Use a certified recovery and recycling cart to prop-

erly remove the refrigerant from the air condition-
ing system.

g01054187
Illustration 282

The in-line dryer is located on left hand side of the

machine in the compartment (1) with the fuel filters.
SEBU7764-10 189
Maintenance Section
Ripper Linkage and Cylinder Bearings - Lubricate

The in-line dryer is accessible by opening the door

to the compartment.

g01017640
Illustration 283

Note: The “R-134a” refrigerant dryer should be

replaced annually. Extremely humid operating
conditions may require more frequent replacement of Illustration 284
g01048827
the dryer. The dryer should also be replaced if the air
conditioning system has been leaking or if the system Lubricate the grease fittings for the hydraulic cylinder
has been opened for service repair. bearings (1), (2), (3) and (4).
Reference: For the correct procedure, refer to
Air Conditioning and Heating Service Manual,
SENR5664 or the Disassembly and Assembly
Manual for your machine.

Note: A qualified mechanic should replace the

components of the refrigerant system since special
tooling and training are required.

i02039230

Ripper Linkage and Cylinder

Bearings - Lubricate
SMCS Code: 6313-086-BD, L4

Note: There are a total of twelve grease fittings for

the ripper linkage and hydraulic cylinder bearings.

g01048866
Illustration 285

Lubricate the remote grease fittings for the pins (5).

190 SEBU7764-10
Maintenance Section
Ripper Tip and Shank Protector - Inspect/Replace

1. Raise the ripper. Place blocking under the ripper.

Lower the ripper onto the blocking. The ripper
should be high enough so that the ripper tip or the
shank protector can be removed. Do not place the
ripper too high.

2. If the ripper tip is worn, drive out the pin. Remove

the tip and the shank pin retainer.

3. Clean the shank pin retainer and the pin.

4. Install the new tip and the retainer.

5. Install the pin from the opposite side of the

retainer.

6. If the shank protector is worn, drive out the pins.

Remove the shank protector.

7. Clean the pin retainers and the pins.

Illustration 286
g01048879 8. Install the new shank protector and the retainers.

Lubricate the grease fittings for the pins (6). 9. Install the pins from the opposite side of the
retainer.

i02039171 10. Raise the ripper and remove the blocking.

Ripper Tip and Shank Protector 11. Lower the ripper to the ground.
- Inspect/Replace
(If Equipped) i03130720

SMCS Code: 6808-040; 6808-510; 6810; 6812-040;

Rollover Protective Structure
6812-510 (ROPS) - Inspect
SMCS Code: 7325-040

Note: The ROPS arrangement typically consists

of the following components: ROPS assembly (1)
(canopy) with upper mounting bolts (A) and ROPS
support assembly (2) with lower mounting bolts (B).
See Illustration 288.

g00945595
Illustration 287
(1) Ripper tip
(2) Shank protector

When the ripper tip is worn close to the shank,

replace the ripper tip. When the shank protector is
worn close to the shank, replace the shank protector.
If the tip is too blunt, the tip will not penetrate properly.
g01609177
Illustration 288
(1) Rollover Protective Structure (ROPS)
SEBU7764-10 191
Maintenance Section
Seat Belt - Inspect

Inspect the ROPS arrangement, the canopy, and Check the seat belt mounting hardware (1) for wear
lower supports for any cracks or damage. If the or for damage. Replace any mounting hardware that
ROPS has any cracks in the welds, in the castings, or is worn or damaged. Make sure that the mounting
in any metal section, consult your Caterpillar dealer bolts are tight.
for repairs.
Check buckle (2) for wear or for damage. If the buckle
Reference: See Special Instruction, SEBU6929, is worn or damaged, replace the seat belt.
“Inspection, Maintenance and Repair of Rollover
Protective Strructures (ROPS) and Attachment Inspect the seat belt (3) for webbing that is worn or
Installation Guidelines” for further guidance frayed. Replace the seat belt if the seat belt is worn
information. or frayed.

Inspect both sides of the Rollover Protective Structure Consult your Caterpillar dealer for the replacement of
(ROPS) for bolts that are loose, broken or damaged. the seat belt and the mounting hardware.
If any broken ROPS bolts (A) or (B) are found,
replace all of ROPS bolts (A ) or (B). Note: Within three years of the date of installation or
within five years of the date of manufacture, replace
Inspect the Rollover Protective Structure (ROPS) the seat belt. Replace the seat belt at the date which
for bolts that are loose or damaged. Replace any occurs first. A date label for determining the age of
damaged bolts and any missing bolts with original the seat belt is attached to the seat belt, the seat belt
replacement parts only. buckle, and the seat belt retractor.

Do not weld reinforcement plates to the ROPS If your machine is equipped with a seat belt
in order to straighten the ROPS. Do not weld extension, also perform this inspection procedure for
reinforcement plates to the ROPS in order to repair the seat belt extension.
the ROPS.
i02429594
Note: Notify your Caterpillar dealer if broken bolts
are found. Seat Belt - Replace
Reference: See “Specifications” in the Service SMCS Code: 7327-510
Manual for information on the bolt torque, if
necessary. Within three years of the date of installation or within
five years of the date of manufacture, replace the
i02429589 seat belt . Replace the seat belt at the date which
occurs first. A date label for determining the age of
Seat Belt - Inspect the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.
SMCS Code: 7327-040

Always check the condition of the seat belt and the

condition of the seat belt mounting hardware before
you operate the machine. Replace any parts that are
damaged or worn before you operate the machine.

g01152685
Illustration 290
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Date of manufacture (tag) (fully extended web)
(4) Date of manufacture (underside) (buckle)

Consult your Caterpillar dealer for the replacement of

the seat belt and the mounting hardware.
g00932801
Illustration 289
Typical example
192 SEBU7764-10
Maintenance Section
Torque Converter Scavenge Screen - Clean

If your machine is equipped with a seat belt Reference: See Operation and Maintenance Manual,
extension, also perform this replacement procedure “Power Train System Oil Level - Check” in order to
for the seat belt extension. fill with oil.

i03967449 i03678988

Torque Converter Scavenge Track - Check/Adjust

Screen - Clean SMCS Code: 4170-036
SMCS Code: 3101-070-MGS

Hot oil and components can cause personal in-

jury.

Do not allow hot oil or components to contact

skin.

After a major power train component failure, clean

the torque converter scavenge screen.

1. Remove the bottom guard in order to gain access Illustration 292

g01048969
to the torque converter.
Check the track adjustment. Check the track for wear
Note: Drain all fluids into a suitable container. and for excessive dirt buildup.

Grease is under high pressure.

Grease coming out of the relief valve under pres-

sure can penetrate the body causing injury or
death.

Do not watch the relief valve to see if grease is es-

caping. Watch the track or track adjustment cylin-
der to see if the track is being loosened.

Loosen the relief valve only one turn.

g01387611
Illustration 291

2. Remove the bolts and drain valve body (1 ) from 1. Move the machine forward. Allow the machine
the torque converter, as shown. to coast to a stop without the use of the service
brakes. Adjust the tracks while you are in the
3. Remove torque converter scavenge screen (2) machine's typical operating conditions. If packing
from the torque converter housing. conditions prevail on the workplace, the tracks
should be adjusted with packing material.
4. Wash the screen in a clean, nonflammable
solvent. 2. To measure the sag in the track, stretch a string
over the grousers that are between the sprocket
5. Install torque converter scavenge screen (2) in and the front idler. Take the measurement from
the torque converter housing. Install the bolts and the string to the top of the grouser at the maximum
drain valve body (1). measurement. Dimension (2) is the maximum
distance between the string and the grouser.
6. Install the bottom guard.
SEBU7764-10 193
Maintenance Section
Track - Check/Adjust

Loose Track Adjustment

g00512026
Illustration 293
Track adjustment without carrier rollers g00945693
Illustration 295
Location of dimension (1)
If a machine does not have carrier rollers, the sag in
the track is measured between the sprocket and the
front idler. The correct adjustment of dimension (2) is
155 ± 10 mm (6.1 ± .40 inch).

g00945710
Illustration 296
Dimension (1)

Illustration 294
g00511982 NOTICE
Track adjustment with carrier rollers Do not attempt to tighten track when dimension (1) is
193 mm (7.6 inch) or more.
If the machine is equipped with a carrier roller, the
correct adjustment of dimension (3) and dimension Contact your Caterpillar dealer for track service or in-
(4) is 75 ± 10 mm (3 ± 0.40 inch). structions.

Note: The sum of dimension (3) and dimension (4)

must be 155 ± 10 mm (6.1 ± 0.40 inch).

g00945717
Illustration 297

1. Remove access cover (5).

194 SEBU7764-10
Maintenance Section
Track - Check/Adjust

g00945711 g00945714
Illustration 298 Illustration 300

2. Add multipurpose grease (MPGM) through 2. Loosen relief valve (7) by one turn of 360 degrees.
track adjustment valve (6). Add the MPGM until Allow the grease to escape.
dimension (2) is correct.
3. Close the relief valve.
3. Operate the machine back and forth in order to
equalize the pressure. Allow the machine to coast
to a complete stop. Do not use the brakes.

4. Remeasure dimension (2).

5. Install access cover (5).

Tight Track Adjustment

g00945711
Illustration 301

4. Add MPGM through track adjustment valve (6).

Add grease until dimension (2) is correct.

5. Install access cover (5).

Bolt Torque for Track Shoes

Illustration 299
g00945717 The torque requirement for track shoe bolts is
870 ± 70 N·m (642 ± 50 lb ft). Tighten the bolts for
1. Remove access cover (5). an additional 120 degrees. If you are using bolts
with a master link, tighten the bolts to a torque of
870 ± 90 N·m (642 ± 66 lb ft). Then, tighten the bolts
for an additional 120 degrees.
SEBU7764-10 195
Maintenance Section
Track Pins - Inspect

i02039746 i02039992

Track Pins - Inspect Track Roller Frame - Inspect

SMCS Code: 4175-040-PN SMCS Code: 4151-040

Fingers can be burned from hot pins and bush-

ings.

The pins and bushings in a dry joint can become

very hot. It is possible to burn the fingers if there
is more than brief contact with these components.

Use the recommendations in order to extend the life

of the undercarriage. Use the recommendations in
order to avoid excessive downtime.
g01049034
Illustration 303

Inspect the track roller frame (3) for leaks. Check the
seal for the pivot shaft (2) for oil leaks. Check the
idlers (1) and track rollers (4) for leaks. Inspect the
seal for the recoil spring (5) for oil leaks.

i02040024

Track Roller Frame Guides -

Inspect
SMCS Code: 4177-040
g01048998
Illustration 302
Measure the rotational movement of the front roller
1. During the machine operation, listen for unusual frame relative to the rear roller frame.
squeaking and for unusual squealing. This can
indicate a dry joint.

2. Check the machine for dry joints weekly. Check

for dry joints immediately after machine operation.
After machine operation, lightly touch the end of
each track pin or bushing. Touch the track pin
or the track bushing with the back of your hand.
Make a mark on any dry track pin joint that is very
hot to the touch.

3. Do not hit the ends of the track pins with a sledge

hammer in order to loosen the track joints.

NOTICE Illustration 304

g01049094
Striking the end of a track pin introduces a significant
amount of end play into the track joint and can result 1. Raise the front of the machine with the hydraulics
in early failures. of the dozer. Place a 100 mm (4 inch) block under
the outside edge of a track shoe. Place the block
Consult your Caterpillar dealer's Custom Track near the track idler. Lower the machine onto the
Service expert if you detect dry joints or leaks. Your block.
Caterpillar dealer's Custom Track Service expert can
perform track inspection.
196 SEBU7764-10
Maintenance Section
Walk-Around Inspection

4. Measure the distance between the two marks on

the front roller frame. If the distance between the
two marks is greater than 4.5 mm (0.18 inch),
inspect the track roller frame guides for wear.

Repeat the entire procedure for the other side of the

machine.

NOTICE
Never build up the track roller frame guides with hard-
face welding. This will cause serious wear damage to
the guide slots in the front track roller frame.

g01049245
Illustration 305

2. Use a grease pencil to make a mark on the tubular

section of the front roller frame. Make a mark
on the rear of the roller frame. This mark should
correspond with the mark that is on the tubular
section.

g00781090
Illustration 308
Track Roller Frame Guide

If dimension (X) is less than 45.3 mm (1.78 inch),

replace the track roller frame guides.

Reference: Refer to Disassembly and Assembly,

“Front Track Roller Frame - Remove” and refer to
g01049226
Disassembly and Assembly, “Front Track Roller
Illustration 306 Frame - Install” in the Service Manual for your
machine. Also, consult your Caterpillar dealer for
3. Raise the front of the machine with the hydraulics more information or for service.
of the dozer. Place the block under the inside
edge of the same track shoe. Lower the machine
onto the block. i03409088

Walk-Around Inspection
SMCS Code: 7000-040

Reference: See Operation and Maintenance Manual,

“Daily Inspection” for more information.

i02775471

Winch Fairlead Rollers -

Lubricate
SMCS Code: 5163-086
g01049273
Illustration 307
If equipped:
SEBU7764-10 197
Maintenance Section
Winch Oil Level - Check

i02094238

Winch Wire Rope - Install

(If Equipped)
SMCS Code: 5154-012; 5163-012

Personal injury or death can result from worn wire

rope cable.

Worn or frayed cable could break causing injury.

g01387081
Illustration 309 Check the wire rope cable. If cable is worn or is
frayed install a new cable.
Lubricate the five fittings. Use MPGM Grease.

i02775441
PA140VS
Winch Oil Level - Check The cable is attached to the drum on the winch with
a cable ferrule. The ferrule is placed into a socket
SMCS Code: 5163-535-FLV on the drum.

If equipped: Use the following table to order the cable.

Table 23
PA140VS Wire Cable
Wire Rope Recommended Holding Capacity
Diameter Ferrule
25 mm (1 inch) L-8 91 m (300 ft)
29 mm J-9 84 m (276 ft)
(1.13 inch)
32 mm J-10 59 m (193 ft)
(1.25 inch)

g01387065
Illustration 310

1. Remove the oil level plug (2) in order to check the

oil level. The oil level should be maintained to the
bottom of the level plug hole.

2. If necessary, remove oil filler plug (1) and add oil.

Check for oil leaks around the covers and around

the hoses. Repair any oil leaks. g01076208
Illustration 311

1. Put the cable in a straight line behind the tractor.

2. Install the ferrule end into the socket.

3. Reel in the cable.

198 SEBU7764-10
Maintenance Section
Window Washer Reservoir - Fill

i02044219 Inspect the front window wiper blade, the side window
wiper blades and the rear window wiper blade.
Window Washer Reservoir - Replace any wiper blades that are damaged or worn.
Fill Replace any wiper blades that streak the window.

SMCS Code: 7306-544 i03131127

NOTICE Windows - Clean

When operating in freezing temperatures, use
Caterpillar or any commercially available nonfreezing SMCS Code: 7310-070; 7340-070
window washer solvent.
If equipped:

Use commercially available window cleaning

solutions to clean the windows.

To clean the outside of the rear window from the

inside of the cab, remove the sliding section of the
rear window. Use the following procedure in order to
remove the sliding section of the rear window.

g01049872
Illustration 312

The washer fluid bottle is on the left side of the

machine above the battery box. Remove the fluid
bottle cap in order to fill the washer fluid bottle.

i02039002

Window Wipers - Illustration 314

g01181500

Inspect/Replace
1. Lift latch (1) in order to slide the small window.
SMCS Code: 7305-040; 7305-510 Squeeze latch (2) in order to move the window
from the CLOSED position.

2. Move handle stop (3) to the UP position. To move

the handle stop to the UP position, lift the handle
and rotate the handle simultaneously. Rotate the
handle until the handle is vertical.

3. Move the small section of the window to opening

(4) in the upper window channel.

4. Tilt the top of the window toward the inside of the

cab. Remove the window.

5. Stay inside the cab in order to clean the outside

of the rear window.
g01058605
Illustration 313
(1) Front window wiper 6. After cleaning, install the sliding section of the rear
(2) Side window wiper window.
(3) Rear window wiper
SEBU7764-10 199
Maintenance Section
Windows - Clean

Cleaning From Ground Level

Note: Use the following method in order to clean a
solid rear window.

Use commercially available window cleaning

solutions in order to clean the windows. Clean the
outside of the windows from the groundor with the
use of a man lift, unless appropriate handholds are
available.

g00566124
Illustration 315
Typical example

Use a pole with a squeegee in order to reach the high

areas of the window.