Safety CAT Intervalos de Mantenimientos

8/16/2019 Safety CAT Intervalos de Mantenimientos

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®© 2010 CaterpillarAll Rights Reserved

MAINTENANCE INTERVALSOperation and MaintenanceManual Excerpt


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SEBU7925-08

July 2008

Operation andMaintenance

ManualD6R Series III Track-Type Tractor

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SAFETY.CAT.COM


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SEBU7925-08 93Maintenance Section

Maintenance Interval Schedule

Every 1000 Service Hours or 6 Months

Battery - Inspect .................................................... 94Lift Cylinder Yoke Bearings - Lubricate ............... 129Rollover Protective Structure (ROPS) and Falling

Object Protective Structure (FOPS) - Inspect ... 133

Torque Converter Scavenge Screen - Clean ...... 134Transmission Breather - Replace ....................... 139Transmission Scavenge Screen - Clean ............. 139Transmission System Oil - Change .................... 139Transmission System Oil Filter - Replace ........... 141Winch Oil and Breather - Change/Clean ............ 145

Every 2000 Service Hours or 1 Year

Final Drive Oil - Change ...................................... 116Hydraulic System Oil - Change ........................... 125Track Roller Frame Guides - Inspect .................. 137

Every Year

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 104

Engine Air Filter Secondary Element - Replace .. 107Refrigerant Dryer - Replace ................................ 132

Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture

Seat Belt - Replace ............................................. 134

Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .. 100Cooling System Water Temperature Regulator -

Replace ............................................................. 105

Every 6000 Service Hours or 4 Years

Engine Valve Lash - Check/Adjust ....................... 114

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 99


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Belts - Inspect/Adjust/Replace

Adjust/Replace

g00850323Illustration 129

Alternato r and Water Pump Belt

1. Loosen bolts (1).

2. Turn adjusting nuts (2) until the correct belt tensionis reached. To achieve the correct belt adjustment,move the alternator inward or move the alternator outward, as required.

3. Tighten bolts (1).


Fan Drive Belt


2. Turn the adjusting nuts (2) until the correct belt

tension is reached. To achieve the correct beltadjustment, move the idler pulley inward or movethe idler pulley outward, as required.



Air conditionin g compresso r belt



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96 SEBU7925-08Maintenance SectionBrakes, Indicators and Gauges - Test

2. Turn adjusting nuts (2) until the correct belttension is reached. To achieve the correct beltadjustment, move the compressor inward or movethe compressor outward, as required.


4. Close the access doors.

Note: Use the same procedure in order to replacethe belts.

Note: If new belts are installed, check the beltadjustment again after 30 minutes of engineoperation.

i02431458

Brakes, Indicators and Gauges

- TestSMCS Code: 4100-081; 7000-081; 7450-081

Inspect the dash panel for broken lenses, indicator lights, and switches.

CMS Functional Test

To ensure pr oper operation of the CMS, check thesystem on a daily basis.


The battery disconnect switch must be ON in order to supply electrical power to the machine so that theelectrical systems will function.

ON – The engine start switch key (1) mustbe turned to the ON position in order tosupply electr ical power to the operator’s

compartment so that the CMS will function.

Turn the engine start key to the ON position. Thesystem should act in the following manner:

• The indicator lights on the top portion of theinstrument panel come on briefly.

• The action light comes on briefly.

• The auxiliary action light comes on briefly.

• The indicator lights on the bottom portion of theinstrument panel flash briefly.

• The action alarm sounds briefly.

• The pointers on the gauges point upward. Then,the pointers point to the left. Then, the pointerspoint to the right. Then, the pointers point to thefinal position.

If the system functions properly, start the engine. If any of the following events occur, do not start theengine:

• The indicator lights on the top portion or the bottomportion of the instrument panel do not come on.

• The action light does not come on.

• The auxiliary action light does not come on.

• The action alarm does not sound.

Complete any necessary repairs before you startthe engine.

Panel Test Switch – With the enginestopped, push test switch (2). Service hourswill appear in the display area until the

switch is pushed. Push the switch and release theswitch until the desired information appears in the

display area. The following type of information isdisplayed:

• Total Service Hours

• Service hours in forward speed range

• Service hours in reverse speed range

• Fault codes


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Brakes, Indicators and Gauges - Test

Braking System (Test)

If the machine moves during the test, reduce the

engine speed immediately, and engage the park-ing brake.

If the machine moved while testing the brakes,consult your Caterpillar dealer for brake inspec-tion and repair. Damaged brakes must be repairedbefore returning the machine to operation.

Note: The machine is capable of driving throughthe brakes in the first speed range.

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.


1. Start the engine.

2. Raise all attachments.

3. Depress the service brake pedal.

4. Release the parking brake.

5. While the brake pedal is depressed, move thedirectional control to the SECOND SPEEDFORWARD position.

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

7. Move the directional control to the NEUTRALposition.

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

9. Make any necessary repairs before you operate

the machine.

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


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98 SEBU7925-08Maintenance SectionBulldozer - Lubricate

i02292200

Bulldozer - Lubricate(Power Angle Tilt Blade)

SMCS Code: 6050-086

g01147520

Illustration 134

Lubricate the Power Angle Tilt Blade at every 250hour interval.

1. Lubricate the bearings on the ends of eachhydraulic cylinder (6 points).

2. Lubricate the bearings on each end of thestabilizer link (2 points).

3. Lubricate the bearings under the cover of thestabilizer link (2 points).

4. Lubricate the trunnion bearing (1 point).


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Cab Filter (Fresh Air) - Clean/Inspect/Replace

i02276929

Cab Filter (Fresh Air) -Clean/Inspect/Replace(If Equipped)

SMCS Code: 7342-040; 7342-070-FI; 7342-070;7342-510; 7342-510-FI


Top view

1. Remove fi lter cover (1) and fi lter element (2). Thefilter cover is in front of the front window of the cab.

2. The filter element can be cleaned by usingpressure air. Use a maximum air pressure of 205 kPa (30 psi). Direct the air from the clean sideto the dirty side.

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

4. Install the filter element.

Note: Clean the filters more often in dusty conditions.

i02277295

Cab Filter (Recirculation) -Clean/Inspect/Replace(If Equipped)

SMCS Code: 7342-040; 7342-070; 7342-510


1. Remove the fi lter element that is positioned in theoperator’s compartment below the left side of thedash.

2. The filter element can be cleaned by usingpressure air. Use a maximum air pressure of 205 kPa (30 psi). Direct the air from the clean sideto the dirty side.

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

4. Install the filter element.

Note: Clean the filters more often in dusty conditions.

i02277330

Cooling System Coolant (ELC)- Change

SMCS Code: 1395-044

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


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100 SEBU7925-08Maintenance SectionCooling System Coolant Extender (ELC) - Add

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect 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 suppliessuitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations andmandates.

Drain the coolant whenever the coolant is dirty or whenever foaming is observed.

The filler cap is located inside the access door in thetop, left side of the radiator guard.

1. Slowly loosen the filler cap in order to relievesystem pressure. Remove the fi ller cap.

2. Remove the access cover. The cover is located inthe front, bottom guard.

3. Remove the plug from the drain valve. Install a12.7 millimeter (.5 inch) pipe into the drain valve.The pipe requires 1/2 - 14 NPTF threads.

4. Clamp a hose to the pipe in order to direct thecoolant into a suitable container.

5. Open the dr ain valve. Allow the coolant to draininto a suitable container.

6. Close the drain valve. Fill the system with asolution which consists of clean water and of cooling system cleaner. The concentration of thecooling system cleaner should be 6 to 10 percent.

7. Start the engine. Run the engine for 90 minutes.Stop the engine. Drain the cleaning solution into asuitable container.

8. While the engine is stopped, flush the system withwater. Flush the system until the draining water is clear.

9. Close the drain valve.

10. Replace the plug in the drain valve and install theaccess cover.

11. Add the coolant solution. See the following topicsin this publication:

• Refill Capacities

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

12. Start the engine. Run the engine without the fi ller cap until the thermostat opens and the coolantlevel stabilizes.

13. Check the coolant level. Make necessaryadjustments to the coolant level.

14. If the gasket is damaged, replace the filler cap.Install the filler cap.

15. Stop the engine.


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

i02277360

Cooling System CoolantExtender (ELC) - Add

SMCS Code: 1395-538

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




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Cooling System Coolant Extender (ELC) - Add

Table 15

“Cat ELC Extender”and the Cooling System Capacity

Cooling System CapacityRecommended

Amount of “CatELC Extender”

65 to 83 L (17 to 22 US gal) 1.60 L (54 oz)

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

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

Extended Life Coolant (ELC)Extender

Use a 8T-5296 Coolant Conditioner Test Kit tocheck the concentration of the coolant.

Personal injury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hot

and under pressure. The radiator and all linesto heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.

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

Cooling System Conditioner contains alkali. Avoidcontact with skin and eyes.


1. The fi ller cap is located inside the access door onthe top, left side of the radiator guard. Loosen theradiator cap slowly in order to relieve pressure.Remove the radiator cap.

2. It may be necessary to drain some coolant from

the radiator so that Extender can be added to thecooling system.

Note: Always discard drained fluids according tolocal regulations.

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

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


3. Add 1.60 L (54 oz) of Extender to the coolingsystem.

4. Start the engine. Run the engine without the fi ller cap until the thermostat opens and the coolant

level stabilizes. Check for leaks.


5. Look into filler tube (1). If necessary, add premixedcoolant in order to correct the coolant level.Maintain the coolant level between area (2) andarea (3) of the filler tube. Adding coolant abovethis area of the fi ller tube will cause the coolant toover flow the cooling system.

6. Replace the radiator cap if the cap gasket isdamaged. Install the radiator cap.


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102 SEBU7925-08Maintenance SectionCooling System Coolant Level - Check

i02277501

Cooling System Coolant Level- Check

SMCS Code: 1353-535-FLV; 1395-535-FLV

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

Steam can cause personal injury.

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

Remove the fill cap slowly to relieve pressure.

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

This machine’s radiator has a surge tank. Thereis no top tank in this cooling system. The surgetank has a filler cap and a sight glass. It is notnecessary to remove the filler cap in order to checkthe coolant level. The sight glass is inside the enginecompartment that is on the front left side of themachine. The fi ller cap is beneath the access door that is on the top left side of the radiator guard.


1. Observe the sight glass in order to verify the levelof the coolant. If the coolant completely covers thesight glass, the coolant level is okay. If the coolantlevel is visible in the sight glass, the coolant is low.

Add coolant in order to fi ll the system.

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

Cooling System Maintenance”.


2. If it is necessary to add coolant, remove the fi ller cap slowly in order to relieve the pressure.


3. Look into fi ller tube (1). Maintain the coolant levelbetween area (2) and area (3) of the fi ller tube.

Adding coolant above this area of the filler tubewill cause the coolant to over flow the coolingsystem. If you need to add coolant daily, check the

cooling system for leaks.

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

5. Install the filler cap.

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


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Cooling System Coolant Sample (Level 1) - Obtain

Use compressed air, high pressure water, or steamto remove dust and debris from the radiator core.However, the use of compressed air is preferred.

i02277521

Cooling System CoolantSample (Level 1) - Obtain

SMCS Code: 1350-008; 1395-008; 1395-554; 7542

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In order to receive the full effect of S·O·S analysis, youmust establish a consistent trend of data. In order to establish a pertinent history of data, performconsistent samplings that are evenly spaced.Supplies for collecting samples can be obtained fromyour Caterpillar dealer.

Level 1 Analysis


Refer to Special Publication, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies

suitable to collect and contain fluids on Caterpillar products.


Note: It is not necessary to obtain a CoolantSample (Level 1) if the cooling system is filledwith Cat ELC (Extended Life Coolant). Coolingsystems that are filled with Cat ELC should havea Coolant Sample (Level 2) that is obtained atthe recommended interval that is stated in theMaintenance Interval Schedule.

Note: Obtain a Coolant Sample (Level 1) if thecooling system is filled with any other coolantinstead of Cat ELC. This includes the followingtypes of coolants.

• Commer cial long life coolants that meet theCaterpillar Engine Coolant Specification -1(Caterpillar EC-1)

• Cat Diesel Engine Antifreeze/Coolant (DEAC)

• Commer cial heavy-duty coolant/antifreeze

Testing the coolant can be done at your Caterpillar dealer. Caterpillar S·O·S Coolant Analysis is the bestway to monitor the condition of your coolant and your cooling system. S·O·S Coolant Analysis is a programthat is based on periodic samples.

Perform a Coolant Analysis (Level 1 ) at 250 hoursfor systems that do not contain extended life coolant(ELC).

Use the following guidelines for proper sampling of the coolant:

• Complete the information on the label for thesampling bottle before you begin to take thesamples.

• Keep the unused sampling bottles stored in plasticbags.

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

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

• Place the sample in the shipping sleeveimmediately after obtaining the sample in order toavoid contamination.

• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.


Right view

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

2. Open the right engine compartment. Remove theprotective cap from the sampling valve.


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104 SEBU7925-08Maintenance SectionCooling System Coolant Sample (Level 2) - Obtain

3. Obtain a sample. For additional informationabout coolant analysis, see Special Publication,SEBU6250, “Caterpillar Machine FluidsRecommendations” or consult your Caterpillar dealer.

4. Replace the protective cap. Close the right sideengine compartment.

Submit the sample for Level 1 analysis.

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

Note: Level 1 results may indicate a need for Level 2 Analysis.

Level 2 is a comprehensive analysis which should beperformed annually. See Operation and MaintenanceManual, “Cooling System Coolant Sample (Level 2) -Obtain” for more information.

i02277557

Cooling System CoolantSample (Level 2) - Obtain

SMCS Code: 1350-008; 1395-008; 1395-554; 7542

Level 2 Analysis

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





Testing the coolant can be done at your Caterpillar dealer. Caterpillar S·O·S Coolant Analysis is the best

way to monitor the condition of your coolant and your cooling system. S·O·S Coolant Analysis is a programthat is based on periodic samples. See Operationand Maintenance Manual, SEBU6250, “Caterpillar Machine Fluid Recommendations”, “S.O.S Coolant

Analysis” for more information.

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


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

2. Open the right side engine compartment. Removethe protective cap from the sampling valve.

3. Obtain a sample. For additional informationabout coolant analysis, see Special Publication,SEBU6250, “Caterpillar Machine FluidsRecommendations” or consult your Caterpillar dealer.

4. Replace the protective cap. Close the left sideengine compartment.


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Cooling System Water Temperature Regulator - Replace

Submit the sample for Level 2 analysis.

i02277639

Cooling System Water

Temperature Regulator -Replace

SMCS Code: 1355-510




Replace the thermostat on a regular basis per themaintenance interval schedule. This reduces thechance of unscheduled downtime and of problemswith the cooling system.

A new thermostat should be installed after the coolingsystem has been cleaned. Install the thermostatwhile the cooling system is completely drained or while the cooling system coolant is drained to a levelthat is below the thermostat housing.

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

Note: If you are only installing a new thermostat,drain the cooling system coolant to a level that isbelow the thermostat housing.

1. Open the right engine compartment.


2. Loosen the hose clamp and remove the hose fromthe elbow. Disconnect the hose assembly fromthe thermostat housing assembly.

3. Remove the bolts from the elbow. Remove theelbow and the thermostat housing assembly.

4. Remove the gaskets, the thermostat, and the sealfrom the thermostat housing.

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

Depending on load, failure to operate with the ther-mostats could result in either an overheating or an

overcooling condition.

NOTICEIf the thermostat is installed incorrectly, it will causethe engine to overheat.

5. Install a new seal in the thermostat housing. Installthe new thermostat and the new gasket. Install thethermostat housing on the engine cylinder head.

6. Install the elbow and the hose. Tighten the hoseclamp.

7. Close the right engine compartment.

8. Replace the coolant that was drained from thesystem. Refer to Operation and MaintenanceManual, “Capacities (Refill)”.


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106 SEBU7925-08Maintenance SectionCutting Edges and End Bits - Inspect/Replace

i02050518

Cutting Edges and End Bits -Inspect/Replace

SMCS Code: 6801-040; 6801-510; 6804-040;

6804-510


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

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

3. Thoroughly clean all contact surfaces.

4. Inspect the opposite side of the cutting edge. If the opposite side of the cutting edge is not worn,turn the opposite side of the cutting edge outwardand install the cutting edge.

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

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

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

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

7. Install all bolts and tighten the bolts to the specifiedtorque. Refer to Operation and MaintenanceManual, “Torques for Ground Engaging Tools”.

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

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

i02229305

Engine Air Filter PrimaryElement - Clean/Replace

SMCS Code: 1051-070; 1051-510-PY; 1054-070-PY;1054-510-PY

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

into the clean side of the filter housing.

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

NOTICEService the engine air fi lters with the engine stopped.

Engine damage could result.

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

NOTICEDo not use the fi lter for longer than one year.

1. Open the engine compartment’s access door, if equipped.


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Engine Air Filter Secondary Element - Replace


2. Remove the air cleaner cover (1). Pull out in order to remove the element.

3. Remove the primary fi lter element (2) from the air cleaner housing.

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


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

the secondary filter element in place while youclean the housing.

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

7. Inspect the primary filter element. Inspect thefilter element for holes and for tears by lookingthrough the fi lter element. Look toward a brightlight. Inspect the element for damaged gaskets or for dented metal parts. Replace damaged fi lters.

Always crush damaged fi lter elements. Properly

discard the filter elements. If you replace theprimary fi lter element, proceed to step 9.

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

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

9. Push the fi lter element firmly in order to properlyseat the element. Write the date on the element, if the primary element is replaced.

10. Install the air cleaner cover.

11. Close the access door, if equipped.

i02281102

Engine Air Filter SecondaryElement - Replace

SMCS Code: 1051-510-SE; 1054-510-SE

NOTICE Always replace the secondary filter element. Never attempt to reuse it by cleaning.

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

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

NOTICEDo not use the fi lter for longer than one year.


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108 SEBU7925-08Maintenance SectionEngine Air Precleaner - Clean

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


1. Open the engine access door, if equipped. Theengine access door is located on the left side of the machine outside the operator’s compartment.

2. Remove the air cleaner housing cover.

3. Remove the primary filter element.

Reference: Refer to Operation and MaintenanceManual, “Engine Air Filter Primary Element -Clean/Replace”.

4. Cover the air inlet opening. Clean the inside of the air cleaner housing.

5. Inspect the gasket between the air inlet and theair cleaner housing. If the gasket is damaged,replace the gasket.


6. Uncover the air inlet opening. Remove thesecondary filter element. Pull out in order toremove the element.

7. Install a new secondary filter element. Pushthe element firmly in order to properly seat theelement. Write the date on the new primaryfilter element, when you install the primary filter element in the machine.

8. Install the primary filter element and the air cleaner housing cover. Tighten the bolts for the air cleaner housing cover finger tight. Do not use a tool totighten the bolts for the air cleaner housing cover.

9. Close the engine access door, if equipped.

i02281103

Engine Air Precleaner - Clean

SMCS Code: 1050-070


1. Inspect the air inlet screen for dirt and for trash.

2. Remove the screen. Clean the screen if thescreen is dirty.

3. Inspect the precleaner tubes for dirt and for dust.

4. Use pressure air to clean the tubes. Put the tubeson a flat surface. Direct the pressurized air intothe tubes from the top. This loosens up the dirt.Install the screens.

NOTICEService the air cleaner only with the engine stopped.Engine damage could result.

i02760445

Engine Cr ankcase Breather -Clean

SMCS Code: 1317-070

1. Open the left engine access door.


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Engine Oil Level - Check


2. Loosen the breather outlet hose clamp. Removethe hose from the engine crankcase breather.

g01249976

Illustration 153

3. Loosen the breather inlet hose clamp. Removethe engine crankcase breather.

4. Check the condition of the cover seal. Replace thecover seal if the cover seal is damaged.

5. Wash the breather element and the breather element cover assembly in a clean nonflammablesolvent.

6. Shake the breather element until the breather element is dry. You may also use pressure air to

dry the br eather element.

7. Check the condition of the hoses. Make sure thatthe inside of the hoses are unobstructed. Replacea hose if the hose is damaged.

8. Install the breather element cover assembly.

9. Install the hoses, the breather outlet hose clamp,and the breather inlet hose clamp.

10. Close the engine access door.

i02281109

Engine Oil Level - Check

SMCS Code: 1302-535-FLV; 1326-535-FLV

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contactskin.

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

1. The level gauge relies on gravity. The machinemust be on a level surface for an accurate check.

2. Open the engine access cover that is on the leftside of the machine.


3. Check the dipstick while the engine is stoppedand the oil is at operating temperature. Maintainthe oil level in the operating area on the dipstick.The operating area is between the add oil markand the full mark.

Note: When you operate the machine on severeslopes, the oil level in the engine crankcase must beat the full mark on the dipstick.


21/58

110 SEBU7925-08Maintenance SectionEngine Oil Sample - Obtain


4. Remove the oil fi ller cap. If necessary, add oil.

5. Clean the oil fi ller cap and install the oil fi ller cap.

6. Close the access cover.

i02281124

Engine Oil Sample - Obtain

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




Refer to Special Publication, NENG2500, “Caterpillar

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


Obtain the sample of the engine oil as close aspossible to the recommended sampling interval. Therecommended sampling interval is every 250 servicehours. In order to receive the full effect of S·O·S oilanalysis, you must establish a consistent trend of data. In order to establish a pertinent history of data,

perform consistent oil samplings that are evenlyspaced.

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


2. Remove the protective cap.

3. Use 169-8373 Fluid Sampling Bottle in order toobtain a sample of the engine oil.

4. Replace the protective cap.


Refer to Operation and Maintenance Manual,“Lubricant Viscosities” for the correct fluid for your machine.


22/58


Engine Oil and Filter - Change

i02281129


SMCS Code: 1308; 1318-510

Selection of the Oil Change Interval

NOTICEThis machine is equipped with an engine that meetsEPA Tier 2, Euro Stage II, or MOC Step 2 emissionregulations. A 500 hour engine oil change interval isavailable, pr ovided that operating conditions and rec-ommended multigrade oil types are met. When theserequirements are not met, shorten the oil changeinterval to 250 hours, or use an S·O·S oil samplingand analysis program to determine an acceptable oilchange interval.

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

Caterpillar oil fi lters are recommended.

Recommended multigrade oil types are listed in Table16. Do not use single grade oils.


API Symbol

Commercial oils that are licensed by the American PetroleumInstitute (API) bear this symbol. Commercial oils that do not bear this symbol are not licensed and these oils are not recommended.Oils that are not listed in Table 16 are not recommended.

Abnormally harsh operating cycles or harshenvironments can shorten the service life of the engine oil. Arctic temperatures, corrosiveenvironments, or extremely dusty conditions mayrequire a reduction in engine oil change intervalsfrom the recommendations in Table 16. Also refer to Special Publication, SEBU5898, “Cold Weather Recommendations For All Caterpillar Machines”.Poor maintenance of air filters or of fuel filtersrequires reduced oil change intervals. See your Caterpillar dealer for more information if this productwill experience abnormally harsh operating cycles or harsh environments.

Table 16

D6R Series IIIEngine Oil Change Interval(1)

Operating Conditions

Severe

FuelSulfur from

0.3% to0.5%

MultigradeOil Type

Normal(2) HighLoad

Factor (3)

above32L (8.5US gal)per hr of fuel

(4)

Altitudeabove

1830 m(6000 ft)

Cat DEOPreferred

500 hr 500 hr 500 hr 250 hr (6)

API CH-411.0

minimum

TBN(4)Preferred

500 hr 500 hr 500 hr 250 hr (6)

API CH-4TBN(4)

below 11.0500 hr 500 hr 250 hr (5) 250 hr (6)

API CG-4 500 hr 250 hr (5) 250 hr (5) 250 hr (6)

(1) The traditional oil change interval for engines is 250 hours.The standard oil change interval in this machine is 500 hours, if the operating conditions and recommended oil types that arelisted in this table are met. Improvements in the engine allowthis engine oil change interval. This new standard interval is notpermitted for other machines. Refer to the applicable Operationand Maintenance Manuals for the other machines.

(2) Normal conditions include these factors: Fuel sulfur below

0.3%, altitude below 1830 m (6000 ft), and good air fi lter andfuel fi lter maintenance. Normal conditions do not include highload factor, harsh operating cycles, or harsh environments.

(3) High load factors can shorten the service life of your engineoil. Continuous heavy load cycles and very little idle timeresult in increased fuel consumption and oil contamination.These factors deplete the oil additives more rapidly. If theaverage fuel consumption of your D6R Series III exceeds32 L (8.5 US gal) per hour, follow the “High Load Factor”recommendations in Table 16. To determine average fuelconsumption, measure average fuel consumption for a periodof 50 to 100 hours. If the application of the machine is changed,the average fuel consumption may change.

(4) For sulfur content above 0.5%, refer to Operation andMaintenance Manual, “Total Base Number (TBN) and FuelSulfur Levels for Direct Injection (DI) Diesel Engines” inManual, SEBU6250.

(5) In order to verify an oil change interval of 500 hours, refer to“Program A” below.

(6) Use “Program B” below to determine an appropriate interval.

Adjustment of the Oil Change Interval

Note: Your Caterpillar dealer has additionalinformation on these programs.

Program A

Verification for an Oil Change Interval of 500 Hours


23/58

112 SEBU7925-08Maintenance SectionEngine Oil and Filter - Change

This program consists of three oil change intervals of 500 hours. Oil sampling and analysis is done at 250hours and 500 hours for each of the three intervalsfor a total of six oil samples. The analysis includesoil viscosity and infrared (IR) analysis of the oil. If all of the results are satisfactory, the 500 hour oil

change inter val is acceptable for the machine in thatapplication. Repeat Program A if you change theapplication of the machine.

If a sample does not pass the oil analysis, take oneof these actions:

• Shorten the oil change interval to 250 hours.

• Proceed to Pr ogram B.

• Change to a preferred oil type in Table 16.

Program B

Optimizing Oil Change Intervals

Begin with a 250 hour oil change interval. The oilchange intervals are adjusted by increments. Eachinterval is adjusted an additional 50 hours. Periodic oilsampling and analysis is done during each interval.The analysis includes oil viscosity and infrared (IR)analysis of the oil. Repeat Program B if you changethe application of the machine.

If an oil sample does not pass the analysis, shortenthe oil change interval, or change to a preferredmultigrade oil type in the listing above.

References

Reference: Form, PEDP7035, “Optimizing OilChange Intervals”

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

Reference: Form, PEDP7076, “Understanding theS·O·S Oil Analysis Tests”

Procedure for Changing the EngineOil and Filter








Left view

If the machine is equipped with a high speed oilchange, use a 126-7539 Nozzle.


Top view

1. Remove the bolt in order to remove the crankcasedrain access cover, which is in the crankcaseguard.


24/58




(1) drain valve(2) shutoff valve(3) drain valve elbow(A) Left view(B) Rear view

2. Install a drain hose (not shown) onto drain valveelbow (3).

3. Open shutoff valve (2). Allow the oil to drain into asuitable container.

4. When the oil has completed draining from thecrankcase, close shutoff valve (2). Remove thehose. Install the crankcase drain access cover inthe crankcase guard.


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

6. Remove the engine oil fi lter element and discardthe engine oil fi lter element properly. Make surethat all of the old filter seal is removed from thefilter base.

7. Apply a thin coat of oil to the seal on the new filter.Install the new engine oil filter element by hand.When the gasket contacts the filter base, tightenthe filter element by an additional 3/4 turn (270degrees). Rotation index marks are on the newfilter element. These rotation index marks are

spaced at 90 degree intervals. Use these rotationindex marks as a guide for proper tightening.


8. Open the left engine access door.

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

10. To ensure that the correct amount of oil wasadded, always measure the oil level with the

engine oil dipstick (5).

Check the “ENGINE STOPPED” side of thedipstick while the engine is stopped. The oil shouldbe cold. Maintain the oil level between the “LOW”mark and the “FULL” mark. This method shouldbe used as reference only, before the engine isstarted.

11. Check the “LOW IDLE” side of the dipstickwhile the engine is running. The oil should beat operating temperature. Maintain the oil levelbetween the “ADD” mark and the “FULL” mark.This is the only accurate way to check the oil level.

12. Close the engine access doors.


25/58

114 SEBU7925-08Maintenance SectionEngine Valve Lash - Check/Adjust

i01959327

Engine Valve Lash -Check/Adjust

SMCS Code: 1102-025; 1102

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

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

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

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

NOTICEMeasure the valve clearance with the engine stopped.To obtain an accurate measurement, allow at least 20

minutes for the valves to cool to engine cylinder headand engine block temperature.

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

Refer to your machine’s Service Manual or your Caterpillar dealer for the complete valve adjustmentprocedure.

i02428064

Equalizer Bar Center Pin -Lubricate

SMCS Code: 7206-086-PN; 7207-086-PN

NOTICE Apply lubricant to the fittings with a hand operatedgrease gun only. Use of pressure operated lubricatingequipment damages the seals.


8F-9866 Grease Gun


Remote Fitting

Lubricate the equalizer bar center pin through theremote fitting. The remote fitting is located on theframe on the left side of the machine. The fitting islocated below the dipstick.

The proper lubricant for the center pin is the “DesertGold”. NLGI 2 grease

Refer to Operation and Maintenance Manual,SEBU6250, “Lubricating Greases” for moreinformation.

i02013412

Equalizer Bar End Pins OilLevel - Check

SMCS Code: 7206-535

NOTICE Apply gear oil through the fittings with a hand oper-ated lubrication pump or a suitable grease gun. Useof pressure operated lubricating equipment damagesthe seals.


26/58


Ether Starting Aid Cylinder - Replace

NOTICEBefore and after the equalizer bar end pin is filled withgear oil, seal (1) must be flush with the equalizer bar. If the seals are not flush, damage to the seals can resultby over filling.



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

2. Check the area for oil leakage. Be sure that theseal is in a neutral position.

3. Remove plug (2).

4. Check the oil level. Oil level (4) should be at thetop of the hex head on the fitting.

5. If the oil level is low, apply the gear oil throughfitting (3) until the gear oil reaches oil level (4) atthe top of the hex head on the fitting. Removeany excess oil. This will maintain a volume of air.The gear oil must be applied with a 7H-1680Lubrication Hand Pump. Refer to Operation andMaintenance Manual, “Lubricant Viscosities” for the correct oil. The gear oil has excellent loadcarrying capacity.

6. Be sure that seals (1) are not pushed out. Pushback the seals if the seals are pushed out.

7. Install plug (2).

Note: MPGM GREASE IS ALLOWED ONLY

FOR A FAILED SEAL. THE SEAL SHOULDBE REPLACED AS SOON AS POSSIBLE. THECOMBINATION OF GEAR OIL AND MPGM IS NOTHARMFUL TO THE MACHINE.

When you operate the machine in arctic conditions,lubricate the equalizer bar with EMGARD EP 75W90gear lubricant. EMGARD EP 75W90 gear lubricant isa synthetic lubricant. This lubricant is available fromHudson Corporation.

i02274149

Ether Starting Aid Cylinder -Replace

SMCS Code: 1456-510-CD


1. Remove the upper engine compartment accesscover on the left side of the machine.

1. The ether canister is mounted on the bracketassembly which is seated toward the front of thecab. Loosen the retaining clamp. Remove the oldcanister by turning the canister counterclockwise.

2. Install the “Quick Start ” canister. Turn the canister clockwise. Hand tighten the canister in order toseal the gasket to the canister. Tighten the clamparound the canister.

Note: The ether starting aid cylinder must be installedwith the appropriate gasket. The gasket must beclean in order to make a proper seal.

3. Close the upper engine compartment accesscover.


27/58

116 SEBU7925-08Maintenance SectionFinal Drive Oil - Change

i02281340

Final Drive Oil - Change

SMCS Code: 4050-535-FLV








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

2. Remove oil fi ller plug (2).

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

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

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

6. Fill the final drive with oil to the bottom of the filler

plug opening. See Operation and MaintenanceManual, “Capacities Refill”.

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

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

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

dealer.

i02281354

Final Drive Oil Level - Check

SMCS Code: 4050-535-FLV




1. Position one final drive so that oil level mark (1) ishorizontal and drain plug (3) is at the bottom.


28/58


Final Drive Oil Sample - Obtain

2. Remove oil fi ller plug (2).

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

See the Table in the article “Lubricant Viscosities”

for the type of oil.

4. Install oil filler plug (2).

5. Repeat Step 1 to Step 4 in order to check the oillevel in the other final drive.

i02281399

Final Drive Oil Sample - Obtain

SMCS Code: 3258-008; 4011-008; 4050-008;4050-SM; 4070-008; 4070-554-SM; 7542-008



NOTICECare must be taken to ensure that fluids are containedduring 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.



Obtain the sample of the differential and final drive oilas close as possible to the recommended samplinginterval. The recommended sampling interval is every500 service hours. In order to receive the full effectof S·O·S oil analysis, you must establish a consistenttrend of data.


1. Position one final drive so that oil level mark (1) ishorizontal. Drain plug (3) should face downward.

2. Remove oil fi ller plug (2) and obtain the oil samplewith a 1U-5718 Vacuum Pump.

Note: Do not use the drain stream method to obtaina sample of the final drive oil. A stream of dirty oilfrom the bottom of the compartment will contaminatethe sample. Likewise, never dip an oil sample froman oil container or pour a sample from a used fi lter.

3. Install oil filler plug (2).

4. Repeat Step 1 to Step 3 in order to sample the oilin the other final drive.

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

Reference: Refer to Special Publication, SEBU6250,“Caterpillar Machine Fluids Recommendations”,“S·O·S Oil Analysis” for information that pertains

to obtaining a sample of the fi

nal drive oil. Refer to Special Publication, PEHP6001, “How To Take A Good Oil Sample” for more information aboutobtaining a sample of the final drive oil.


29/58

118 SEBU7925-08Maintenance SectionFront Idler Position - Check

i02296034

Front Idler Position - Check

SMCS Code: 4159

SystemOne Undercarriage

The following check is for Caterpillar SystemOneUndercarriages that have the center tread idler.


Elevated undercarriage system

1. Park the machine on a hard, flat surface. Makesure that the bottom track is tight and that themeasured grouser lies directly below the trackidler shaft.

2. Measure the height (A, B) from the flat groundsurface to the grouser tip that is centered belowthe track idler shaft.

3. Maintain the grouser height (rise) to the followingdimensions.

a. (A) Front Idlers

Minimum – 0 mm (0 inch)

Maximum – 20 mm (0.8 inch)

b. (B) Rear Idlers

Minimum – 10 mm (0.4 inch)

Maximum – 40 mm (1.6 inch)

4. Repeat Steps 1 through 3 in order to determinethe proper height dimension under each idler.


Adjustme nt shim (center tread idler)

5. For machines with the SystemOne Undercarriage,remove one shim under each track idler block

when the wear on the link and roller system is at50%.

Consult your Caterpillar dealer for detailedinformation about adjustments to the center treadidler.

See Operation and Maintenance Manual, “Track- Check/Adjust” for information on needed trackadjustments.

Reference: See Operation and MaintenanceManual, “Reference Material” for publications andSpecial Instructions on removal and installation of

SystemOne Track, as needed.

Conventional Design

g00669323Illustr ation 173

(A) Adjusting shims(B) Dimension between the height of the front idler tread and the

height of the roller tread

The following check is for undercarriage systems thathave the conventional idler.


30/58

SEBU7925-08 119Maintenance SectionFuel System - Prime

The height of the front idler tread should alwaysbe higher than the height of the roller tread.The dimension (B) is set approximately to 9.0 mm(.35 inch) at the factory. Dimension (B) decreasesas the undercarriage wears. If a rebuilt idler or anew idler is installed with track rollers that are worn,

dimension (B) decreases.

Adjustment of the front idler to the correct height canimprove the r ide of the tractor and the performance of the dozer. Use the following procedures to determinethe best operating position.

If the machine is operated on FIRM UNDERFOOTconditions and excess vibration occurs, shims can beremoved in order to raise the front idler.

If the machine is operated on SOFT UNDERFOOTconditions and dozing performance is poor, shims canbe installed in order to lower the front idler. Lowering

the front idler can improve dozing performance. If ground rippling by the dozer or excess vibration occur in soft material, shims can be removed in order toraise the front idler.

Consult your Caterpillar dealer for detailedinformation about checking the idler and aboutadjustments to the idler.

i02572431

Fuel System - Prime

SMCS Code: 1258

Personal injury or death can result from a fire.

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

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

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



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


If the engine does not start, air may be trapped in thefuel lines to the engine. Use the following procedure

in order to purge air from the fuel lines.

Electric Fuel Priming Pump

The electric fuel priming pump is located in theengine compartment on the left side of the machine.


1. Move the switch for the electric fuel priming pumpto the ON position. Allow the fuel priming pump torun for several seconds.

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

OFF position.

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

Note: The electric fuel priming pump will only operateif the engine start switch key is in the OFF position.Shut off the engine before any additional priming.

4. Run the engine at the LOW IDLE position until theengine runs smoothly.


31/58

120 SEBU7925-08Maintenance SectionFuel System Secondary Filter - Replace

Note: Do not activate the priming pump while youcrank the engine.

i02398364

Fuel System Secondary Filter -Replace

SMCS Code: 1261-510-SE

Personal injury or death can result from a fire.





Refer to Special Publication, NENG2500, “Caterpillar

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


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

Before you replace the secondary fuel fi

lter element,replace the primary fuel fi lter element.


1. Turn the red handle of the fuel shutoff valveclockwise in order to shut off the fuel supply. Thefuel shutoff valve is located at the rear of the

machine under the fuel tank.

2. Open the engine access door on the left side of the machine. The secondary fuel filter is mountedon the left side of the engine behind the primaryfuel filter.


Front view

3. Remove the secondary fuel fi lter. Drain the fuelinto a suitable container.

Note: Discard any drained fluids according to local

regulations. Discard the fuel filter properly.

4. Clean the fi lter base. Make sure that all of the oldseal is r emoved.

5. Coat the seal of the new high ef ficiency fuel filter with clean diesel fuel.

6. Install the new fuel filter by hand. When theseal contacts the base, tighten the filter for anadditional 3/4 turn.


32/58


Fuel System Water Separator - Drain

Rotation index marks are positioned on the filter at 90 degree intervals. Use these rotation indexmarks as a guide when you tighten the fi lter.

7. Open the fuel shutoff valve. Refer to illustration175.

8. Prime the fuel system. See the Topic “Fuel System- Prime” in this manual.


i02009564

Fuel System Water Separator - Drain

SMCS Code: 1263-543

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

NOTICECare must be taken to ensure that fluids are containedduring perf ormance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-




NOTICEDo not allow dirt to enter the fuel system. Thoroughly

clean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over discon-nected fuel system component.


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

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

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

2. Close drain (3).

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

i02281652

Fuel System Water Separator Element - Replace

SMCS Code: 1263-510-FQ

Personal in jury or death may result from failure toadhere to the following procedures.





33/58

122 SEBU7925-08Maintenance SectionFuel System Water Separator Element - Replace

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





1. The fuel shutoff valve is located at the rear of themachine under the fuel tank. Turn the red handleof the fuel shutoff valve in order to shut off thefuel supply.

2. Remove the access cover on the left side of theengine compartment.


3. In order to drain primary filter (1), open drainvalve (3) on water separator bowl (2). The water separator bowl is under primary filter (1). Catch

the fuel in a suitable container.

Note: Discard any drained fluids according to localregulations.

4. Remove primary filter (1) and water separator bowl (2).

5. Remove water separator bowl (2) from the primaryfilter element (1).

6. Wash water separator bowl (2) in a cleannonflammable solvent. Use pressure air to drywater separator bowl (2).

7. Install the clean water separator bowl onto a newprimary fi lter element.

8. Wash the filter mounting base in clean,nonflammable solvent. Make sure that all of theold seal is removed.

9. Coat the seal of the new fi lter element with cleandiesel fuel.

10. Install the new fi lter element by hand. When theseal contacts the base, tighten the fi lter elementfor an additional 3/4 turn.

Rotation index marks are positioned on the fi lter elements at 90 degree intervals. Use theserotation index marks as a guide when you tightenthe filter.

11. Open the fuel shutoff valve.

12. Prime the fuel system, if the machine is equippedwith a priming pump.

Refer to the Operation and Maintenance Manual,“Fuel System - Prime” for the proper procedure.


34/58


Fuel Tank Cap Filter and Strainer - Replace/Clean

13. Install the access cover.

i02281929

Fuel Tank Cap Filter and

Strainer - Replace/CleanSMCS Code: 1273-070-STR; 1273-070-Z2


The fuel tank is located on the rear of the machine.The filler cap is on the left side of the machine next tothe ROPS.


1. Lift lever (3) in order to remove the fuel tank filler cap. Turn the lever counterclockwise until the

lever stops. Lift the cap straight up in order toremove the cap.

2. Remove the fuel strainer from the fi ller neck.

3. In order to replace the fi lter assembly, remove twoscrews that secure fi lter assembly (2) to the fuelcap. Remove filter assembly (2), valve (1), andthe gaskets.

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

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

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

7. Install the strainer.

8. Install the fuel cap. Rotate the fuel cap clockwiseuntil three tabs (5) drop into the slots in theadapter. Rotate lever (3) clockwise until the lever stops. Lower lever (3) over locking tab (4).

i02281990

Fuel Tank Water and Sediment- Drain

SMCS Code: 1273-543-M&S





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

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

2. Close the drain valve.


35/58

124 SEBU7925-08Maintenance SectionFuses and Circuit Breakers - Replace/Reset

i02281991

Fuses and Circuit Breakers -Replace/Reset

SMCS Code: 1417-510; 1420-529; 1420

Fuses – Fuses protect the electricalsystem from damage that is caused byoverloaded electrical circuits. Replace

a fuse if the element separates. If the fuse of a particular electrical system requires frequentreplacement, check the electrical circuit. Repair theelectrical circuit, if necessary.

NOTICE Always replace fuses with the same type and capacityfuse that was removed. Otherwise, electrical damagecould result.

NOTICEIf it is necessary to replace fuses frequently, an elec-trical problem may exist.

Contact your Caterpillar dealer.


Raised cover (battery box)

Raise the battery box cover on the right side of the machine. Open the access door to the circuitbreakers and the fuses.


Circuit breaker, cover, and line fuse

Fuses are located behind cover (25).

Line Fuse (27) – 175 Amp

Fuses


Fuses

A film for the fuse panel is on the inside of the batterybox cover.

Wipers (1) – 15 Amp

Accugrade 1 (2) – 15 Amp

Monitoring System (3) – 15 Amp

Accurgrade 2 (4) – 10 Amp

Implement or Drive train (5) – 15 Amp

Auxiliary Switch (6) – 15 Amp


36/58


Hydraulic System Oil - Change

Fuse for the ripper pin puller, for the seat, and for the winch (7) – 10 Amp

Floodlights on Fender (8) – 15 Amp

Flood Lights (Rear) (9) – 15 Amp

Switching Type Converter (10) – 10 Amp

Refrigerant Condenser (1) (ROPS) (11) – 15 Amp

Refrigerant Condenser (2) (ROPS) (12) – 15 Amp

Forward Horn (13) – 15 Amp

Ignition Key (14) – 15 Amp

Service Brake (15) – 15 Amp

Flood Lights (Front) (16) – 15 Amp

Product Link (17) – 15 Amp

Converter (18) – 10 Amp

Machine ECM (19) – 15 Amp

Unswitched Fuse (20) – 15 Amp

Engine ECM (21) – 15 Amp

24 Volt to 12 Volt Converter (22) – 20 Amp

Spare (23) – 15 Amp

Spare (24) – 15 Amp

Circuit Breakers

Circuit Breaker/Reset – Push in thebutton in order to reset the circuit breaker.If the electr ical system is working properly,

the button will remain depressed.

Note: If the button does not remain depressed, checkthe appropriate electrical circuit. Repair the electricalcircuit, if necessary.

Blower (26) – Circuit Breaker

i02282123

Hydraulic System Oil - Change

SMCS Code: 5050-044

Note: The normal hydraulic oil change intervalis at every 2000 Service Hours or 1 Year. Byperforming S·O·S oil analysis, the hydraulicoil change interval may be extended to 4000Service Hours or 1 Year. S·O·S oil analysis mustbe performed at every 500 Service Hours or 3 Months in or der to extend the hydraulic oilchange interval. The results from the S·O·S oilanalysis will determine if the hydraulic oil changeinterval may be extended. If S·O·S oil analysis isnot available, the hydraulic oil change intervalmust remain at every 2000 Service Hours or 1

Year . Refer to the Operation and MaintenanceManual, “Hydraulic System Oil Sample - Obtain”.

Machines that are used in severe conditions arenot included in the 4000 hour maintenance interval.Machines that are used in severe conditions mustuse the interval in the Maintenance Interval Schedule.

Lubricants

Approved hydraulic oil must be used to obtain the4000 hour hydraulic oil change. Refer to the list thatfollows for approved oils.

Caterpillar Hydraulic Oils

• “Cat HYDO”

• TDTO

• Hydraulic environmental ester synthetic (HEES)

• MTO

Commercial Oils

Diesel engine oils (Heavy Duty) with a minimumzinc content of 900 ppm can be used. Acceptablecommercial oils are identified by the American

Petroleum Institute trademark (“API”). Refer to the listthat follows for acceptable types of hydraulic oils.

• CF

• CF-4

• CG-4

• CH-4


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126 SEBU7925-08Maintenance SectionHydraulic System Oil - Change

Note: Industrial hydraulic oils are not recommendedfor the hydraulic systems of Caterpillar machines.Industrial hydraulic oils are more likely to allowcorrosion and industrial hydraulic oils are more likelyto allow excessive wear.

Change the Hydraulic Oil

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

Hot oil and components can cause personal injury. Do not allow hot oil or components to contactskin.

Remove the filler cap only when the engine isstopped, and the filler cap is cool enough to

touch with your bare hand. Remove the filler capslowly in order to relieve pressure.


Refer to Special Publication, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies

suitable to collect and contain fluids on Caterpillar products.


Operate the machine in order to warm the oil.

Park the machine on level ground. Lower thebulldozer blade to the ground and apply slightdownward pressure. If equipped, lower the ripper tothe ground. Engage the parking brake and stop theengine.


Right side of cab

1. Remove hydraulic tank filler cap (1) slowly in order to relieve any pressure.

2. Wash the fi ller strainer and the filler cap in a cleannonflammable solvent.

3. Use a 126-7914 Oil Drain Coupling and attach a1 inch hose. Make sure that enough of the swivelhose bypasses the track assembly and fills into asuitable container.

4. Remove oil drain plug (3) which is located under the right fender of the machine.

5. Install the swivel hose into the drain plug opening.

6. Rotate the swivel hose clockwise in order to openthe internal drain valve. Allow the oil to drain into asuitable container.

7. Remove the swivel hose. The internal drain valvefor the hydraulic tank will close.

8. Clean the drain plug and install the drain plug.Tighten the drain plug to a torque of 68 ± 7 N·m(50 ± 5 lb ft).

9. Change the hydraulic system filter.

Reference: See Operation and Maintenance

Manual, “Hydraulic System Oil Filter - Replace”.

10. Install the filler strainer.

11. Fill the hydraulic oil tank.

Reference: See Operation and MaintenanceManual, “Lubricant Viscosities and Capacities(Refill)” for additional information.

12. Inspect the fi ller cap gasket. Replace the gasket if damage or wear is evident.

13. Install the fi ller cap.


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Hydraulic System Oil Filter - Replace

14. Start the engine. Operate the engine for a fewminutes.


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

gauge (2). Add oil, if necessary.

16. Stop the engine.

i02282242

Hydraulic System Oil Filter -Replace

SMCS Code: 5068-510



Remove the filler cap only when the engine isstopped, and the filler cap is cool enough totouch with your bare hand. Remove the filler capslowly in order to relieve pressure.





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

g01142202

Illustration 188Right side of cab

2. Slowly remove hydraulic tank fi ller cap (2) in order to relieve the system pressure.

3. Remove retaining nuts (1).

Note: Both the case drain fi lter and the implementreturn fi lter are inside the hydraulic tank.

4. Remove the cover and remove the oil filter fromeach housing. Perform the following steps for each oil filter.

5. Remove the filter element. Properly dispose of thefilter element.

Apply a thin coat of oil to the seal on the new fi lter element.

6. Install the filter element by hand. After the sealcontacts the base, tighten the fi lter element by anadditional 3/4 turn (270 degrees).

7. Remove the retainer ring from the oil fi ller tube.

8. Remove the strainer from the oil fi ller tube.


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128 SEBU7925-08Maintenance SectionHydraulic System Oil Level - Check

9. Wash the screen in a clean nonflammable solvent.

10. Inspect the seal on the fi ller cap. Replace the sealif the seal is worn or if the seal is damaged.

11. Install the strainer, the retainer ring, and the cap.


12. Maintain the hydraulic oil to the “FULL” mark inthe sight gauge.

i02282312

Hydraulic System Oil Level -Check

SMCS Code: 5056-535-FLV; 7479



Remove the filler cap only when the engine isstopped, and the filler cap is cool enough totouch with your bare hand. Remove the filler capslowly in order to relieve pressure.

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

The hydraulic tank is on the right fender of themachine.


1. Maintain the oil level to the “FULL” mark in thesight gauge. Check the oil level when the oil iscold. Verify that the oil level is below the “FULL”

mark before you remove the fi ller cap.


2. If the hydraulic system requires additionalhydraulic oil, remove the fi ller cap slowly in order to relieve any pressure. Add oil through the fi ller tube.

3. Clean the fi ller cap and install the fi ller cap.

i02282329

Hydraulic System Oil Sample- Obtain

SMCS Code: 5095-008




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Lift Cylinder Yoke Bearings - Lubricate





Obtain the hydraulic oil sample as close as possibleto the recommended sampling interval. The

recommended sampling interval is every 500 servicehours. In order to receive the full effect of S·O·S oilanalysis, you must establish a consistent trend of data. In order to establish a pertinent history of data,perform consistent oil samplings that are evenlyspaced.

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

1. Open the access cover on the right side of the cabthat is in front of the hydraulic tank.

g01142283

Illustration 192The hydraulic oil sampling valve is shown.

2. Remove the protective cap.

3. Use 8T-9190 Fluid Sampling Bottle (1) to obtainthe sample.

4. After you take a sample, remove the cap with theprobe from the bottle. Discard the cap with theprobe. Install the sealing cap that is provided with8T-9190 Fluid Sampling Bottle (1).

5.

Safety CAT Intervalos de Mantenimientos

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