Professional Documents
Culture Documents
2010 Caterpillar
All Rights Reserved
SEBU7925-08
July 2008
Operation and
Maintenance
Manual
D6R Series III Track-Type Tractor
GJB1-Up (Machine)
WCB1-Up (Machine)
HDC1-Up (Machine)
RFC1-Up (Machine)
TBC1-Up (Machine)
HCD1-Up (Machine)
HKE1-Up (Machine)
WRG1-Up (Machine)
MTJ1-Up (Machine)
DMK1-Up (Machine)
JEK1-Up (Machine)
EXL1-Up (Machine)
JDL1-Up (Machine)
DLM1-Up (Machine)
LFM1-Up (Machine)
LGP1-Up (Machine)
DPS1-Up (Machine)
GMT1-Up (Machine)
MRT1-Up (Machine)
EXW1-Up (Machine)
SAFETY.CAT.COM
92
Maintenance Section
Maintenance Interval Schedule
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When Required
Cutting Edges and End Bits - Inspect/Replace ... 106
Engine Air Filter Primary Element - Clean/
Replace ............................................................. 106
Engine Air Filter Secondary Element - Replace .. 107
Engine Air Precleaner - Clean ............................ 108
Ether Starting Aid Cylinder - Replace .................. 115
Front Idler Position - Check ................................. 118
Fuel System - Prime ............................................ 119
Fuses and Circuit Breakers - Replace/Reset ...... 124
Oil Filter - Inspect ................................................ 129
Radiator Core - Clean ......................................... 130
Radiator Pressure Cap - Clean/Replace ............ 131
Ripper Tip and Shank Protector - Inspect/
Replace ............................................................. 133
Trunnion Bearing - Adjust ................................... 143
Winch Wire Rope - Install ................................... 145
Window Washer Reservoir - Fill .......................... 146
Windows - Clean ................................................. 147
SEBU7925-08
Every Year
Cooling System Coolant Sample (Level 2) Obtain ............................................................... 104
Engine Air Filter Secondary Element - Replace .. 107
Refrigerant Dryer - Replace ................................ 132
93
Maintenance Section
Maintenance Interval Schedule
94
Maintenance Section
Angle Blade Manual Tilt Brace - Lubricate
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Illustration 128
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i01376996
Battery - Inspect
SMCS Code: 1401-040
Illustration 127
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i02274792
Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510
Inspect
1. Open the access door on the right side of the
machine. Open the access door on the left side of
the machine in order to inspect the air conditioning
compressor belt.
Note: Even if only one belt is worn or damaged,
replace the belts in sets.
2. Inspect the condition of the fan drive belt, the
alternator and water pump belt, and the air
conditioning compressor belt. The belts should
deflect 14 to 20 mm (.56 to .81 inch) under 110 N
(25 lb) of force. Use a 144-0235 Belt Tension
Gauge in order to measure the tension.
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95
Maintenance Section
Belts - Inspect/Adjust/Replace
Adjust/Replace
Illustration 130
Illustration 129
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g00850322
Illustration 131
Air conditioning compressor belt
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96
Maintenance Section
Brakes, Indicators and Gauges - Test
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97
Maintenance Section
Brakes, Indicators and Gauges - Test
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.
Illustration 133
g01043985
98
Maintenance Section
Bulldozer - Lubricate
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Bulldozer - Lubricate
(Power Angle Tilt Blade)
SMCS Code: 6050-086
g01147520
Illustration 134
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99
Maintenance Section
Cab Filter (Fresh Air) - Clean/Inspect/Replace
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i02277295
Illustration 135
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Top view
Illustration 136
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100
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
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.
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Illustration 137
Refill Capacities
g00533931
i02277360
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101
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
Table 15
Recommended
Amount of Cat
ELC Extender
1.60 L (54 oz)
Illustration 139
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102
Maintenance Section
Cooling System Coolant Level - Check
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Illustration 141
Illustration 142
Illustration 140
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g01140173
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Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
Level 1 Analysis
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Illustration 143
g01140364
Right view
104
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
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NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
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.
Testing the coolant can be done at your Caterpillar
dealer. Caterpillar SOS Coolant Analysis is the best
way to monitor the condition of your coolant and your
cooling system. SOS Coolant Analysis is a program
that is based on periodic samples. See Operation
and Maintenance Manual, SEBU6250, Caterpillar
Machine Fluid Recommendations, S.O.S Coolant
Analysis for more information.
Perform a Coolant Analysis (Level 2) at initial 500
hours for systems that contain extended life coolant
(ELC). Perform the analysis yearly after the initial
500 hours.
Level 2 Analysis
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both
dealers and customers.
Illustration 144
g01140364
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105
Maintenance Section
Cooling System Water Temperature Regulator - Replace
Illustration 145
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106
Maintenance Section
Cutting Edges and End Bits - Inspect/Replace
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NOTICE
Extremely short air filter life can result if the precleaner system malfunctions. If air filter life is drastically reduced from typical for the operating conditions, consult your Caterpillar Dealer. The exhaust system dust
ejector for the strata tube precleaner must pull a minimum vacuum of 508 mm (20 inch) of water.
NOTICE
Service the engine air filters with the engine stopped.
Engine damage could result.
NOTICE
Always leave the secondary filter element in place
while you clean the primary element, or while you
clean the air cleaner housing.
NOTICE
Do not use the filter for longer than one year.
1. Open the engine compartments access door, if
equipped.
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107
Maintenance Section
Engine Air Filter Secondary Element - Replace
Illustration 147
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108
Maintenance Section
Engine Air Precleaner - Clean
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NOTICE
Always leave the secondary filter element in place
while you clean the primary element, or while you
clean the air cleaner housing.
Illustration 149
g01141636
Illustration 151
g01141638
1. Inspect the air inlet screen for dirt and for trash.
2. Remove the screen. Clean the screen if the
screen is dirty.
3. Inspect the precleaner tubes for dirt and for dust.
4. Use pressure air to clean the tubes. Put the tubes
on a flat surface. Direct the pressurized air into
the tubes from the top. This loosens up the dirt.
Install the screens.
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.
i02760445
Illustration 150
g00470240
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109
Maintenance Section
Engine Oil Level - Check
i02281109
g01381893
NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
1. The level gauge relies on gravity. The machine
must be on a level surface for an accurate check.
2. Open the engine access cover that is on the left
side of the machine.
Illustration 153
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Illustration 154
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110
Maintenance Section
Engine Oil Sample - Obtain
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Illustration 155
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Illustration 156
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111
Maintenance Section
Engine Oil and Filter - Change
i02281129
Table 16
Operating Conditions
Severe
Normal(2)
Multigrade
Oil Type
High
Load
Factor(3)
above
32 L (8.5
US gal)
per hr
of fuel
Fuel
Sulfur
from
0.3% to
0.5%
Altitude
above
1830 m
(6000 ft)
(4)
Cat DEO
Preferred
500 hr
500 hr
500 hr
250 hr(6)
API CH-4
11.0
minimum
TBN(4)
Preferred
500 hr
500 hr
500 hr
250 hr(6)
API CH-4
TBN(4)
below 11.0
500 hr
500 hr
250 hr(5)
250 hr(6)
API CG-4
500 hr
250 hr(5)
250 hr(5)
250 hr(6)
Illustration 157
g00753767
API Symbol
Commercial oils that are licensed by the American Petroleum
Institute (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.
(1)
112
Maintenance Section
Engine Oil and Filter - Change
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NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Illustration 158
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Left view
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Illustration 159
Top view
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113
Maintenance Section
Engine Oil and Filter - Change
Illustration 160
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Illustration 162
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Illustration 161
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114
Maintenance Section
Engine Valve Lash - Check/Adjust
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Illustration 163
g01139573
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
NOTICE
Operation of Caterpillar engines with improper valve
adjustments will reduce engine efficiency. This reduced efficiency could result in excessive fuel usage
and/or shortened engine component life.
NOTICE
Measure the valve clearance with the engine stopped.
To obtain an accurate measurement, allow at least 20
minutes for the valves to cool to engine cylinder head
and engine block temperature.
Check the valve bridge before setting the valve lash.
Ensure that the valve bridge is seated equally on
both valve stems.
Refer to your machines Service Manual or your
Caterpillar dealer for the complete valve adjustment
procedure.
Illustration 164
g01139561
Remote Fitting
i02428064
i02013412
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115
Maintenance Section
Ether Starting Aid Cylinder - Replace
NOTICE
Before and after the equalizer bar end pin is filled with
gear oil, seal (1) must be flush with the equalizer bar. If
the seals are not flush, damage to the seals can result
by overfilling.
Illustration 165
g00586840
Illustration 166
g00586858
1. Clean the areas that are around the end pin with a
high pressure wash. Inspect the condition of the
seal (1).
2. Check the area for oil leakage. Be sure that the
seal is in a neutral position.
3. Remove plug (2).
4. Check the oil level. Oil level (4) should be at the
top of the hex head on the fitting.
5. If the oil level is low, apply the gear oil through
fitting (3) 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.
The gear oil must be applied with a 7H-1680
Lubrication Hand Pump. Refer to Operation and
Maintenance Manual, Lubricant Viscosities for
the correct oil. The gear oil has excellent load
carrying capacity.
Illustration 167
g01138860
116
Maintenance Section
Final Drive Oil - Change
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6. Fill the final drive with oil to the bottom of the filler
plug opening. See Operation and Maintenance
Manual, Capacities Refill.
Hot oil and components can cause personal injury.
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, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Illustration 168
g01141777
g01141777
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117
Maintenance Section
Final Drive Oil Sample - Obtain
g01141813
2. Remove oil filler plug (2) and obtain the oil sample
with a 1U-5718 Vacuum Pump.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
118
Maintenance Section
Front Idler Position - Check
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SystemOne Undercarriage
The following check is for Caterpillar SystemOne
Undercarriages that have the center tread idler.
Illustration 172
g01151486
g01149978
Conventional Design
Illustration 173
g00669323
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119
Maintenance Section
Fuel System - Prime
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
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.
i02572431
Illustration 174
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120
Maintenance Section
Fuel System Secondary Filter - Replace
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Illustration 175
g01141950
NOTICE
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
system parts.
Before you replace the secondary fuel filter element,
replace the primary fuel filter element.
g01141951
Front view
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121
Maintenance Section
Fuel System Water Separator - Drain
Illustration 177
g00104007
(1) Element
(2) Bowl
(3) Drain
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tightened securely to help prevent air from entering the fuel
system.
i02281652
122
Maintenance Section
Fuel System Water Separator Element - Replace
SEBU7925-08
NOTICE
Do not fill fuel filter with fuel before installing the fuel
filter. Contaminated fuel causes accelerated wear to
fuel system parts.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
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.
Illustration 179
g01141926
Illustration 178
g01141906
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123
Maintenance Section
Fuel Tank Cap Filter and Strainer - Replace/Clean
Illustration 180
g01141983
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
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.
Illustration 181
g01141982
Illustration 182
g01141998
124
Maintenance Section
Fuses and Circuit Breakers - Replace/Reset
SEBU7925-08
i02281991
NOTICE
Always replace fuses with the same type and capacity
fuse that was removed. Otherwise, electrical damage
could result.
NOTICE
If it is necessary to replace fuses frequently, an electrical problem may exist.
g01142009
Fuses
Illustration 183
g00984827
Illustration 185
g01142008
Fuses
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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 the
button in order to reset the circuit breaker.
If the electrical system is working properly,
the button will remain depressed.
Note: If the button does not remain depressed, check
the appropriate electrical circuit. Repair the electrical
circuit, if necessary.
Blower (26) Circuit Breaker
125
Maintenance Section
Hydraulic System Oil - Change
i02282123
Lubricants
Approved hydraulic oil must be used to obtain the
4000 hour hydraulic oil change. Refer to the list that
follows for approved oils.
CF
CF-4
CG-4
CH-4
126
Maintenance Section
Hydraulic System Oil - Change
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Illustration 186
g01142101
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
SEBU7925-08
127
Maintenance Section
Hydraulic System Oil Filter - Replace
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
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.
Illustration 187
g01142156
Illustration 188
g01142202
128
Maintenance Section
Hydraulic System Oil Level - Check
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Illustration 190
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Illustration 191
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129
Maintenance Section
Lift Cylinder Yoke Bearings - Lubricate
Illustration 193
g01142312
i02106227
Illustration 192
g01142283
Illustration 194
The element is shown with debris.
g00100013
130
Maintenance Section
Pivot Shaft Oil Level - Check
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Illustration 196
g00100624
Illustration 195
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131
Maintenance Section
Radiator Pressure Cap - Clean/Replace
i02282497
i02282842
Illustration 198
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Illustration 197
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Front view
Illustration 199
g01110810
132
Maintenance Section
Refrigerant Dryer - Replace
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Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.
g01147674
Illustration 201
g01147675
3. Remove the bolt and the clip that retains the dryer.
The lines that connect to the dryer are equipped
with quick disconnects. Remove the dryer.
4. Install a new dryer.
5. Install the bolt and the clip.
6. Fasten the connections to the dryer.
7. Close the access door.
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133
Maintenance Section
Ripper Linkage and Cylinder Bearings - Lubricate
i00072976
g00103773
Illustration 203
g00550432
134
Maintenance Section
Seat Belt - Inspect
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i02429594
Illustration 204
g00932801
Typical example
Illustration 205
(1)
(2)
(3)
(4)
g01152685
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135
Maintenance Section
Track - Check/Adjust
i02283030
Track - Check/Adjust
SMCS Code: 4170-036
Illustration 206
g01143801
Front view
Illustration 208
g01142731
g00822757
Do not watch the relief valve to see if grease is escaping. Watch the track or track adjustment cylinder to see if the track is being loosened.
Loosen the relief valve one turn only.
If track does not loosen, close the relief valve and
contact your Caterpillar dealer.
1. Move the machine forward. Allow the machine
to coast to a stop without the use of the service
brakes. Adjust the tracks while you are in the
machines typical operating conditions. If packing
conditions prevail on the workplace, the tracks
should be adjusted without removing the packed
material.
2. To measure the sag in the track, stretch a string
over the grousers that are between the sprocket
and the front idler. Take the measurement from
the string to the top of the grouser at the maximum
measurement. Dimension (A) is the maximum
distance between the string and the grouser.
136
Maintenance Section
Track - Check/Adjust
SEBU7925-08
NOTICE
Do not attempt to tighten track when dimension (1) is
150 mm (5.9 inch) or more.
Contact your Caterpillar dealer for track service or instructions.
1. Remove the access cover.
Illustration 209
g01109482
Illustration 212
g01019116
g01118207
Illustration 211
g01019107
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137
Maintenance Section
Track Pins - Inspect
i01967485
SystemOne Undercarriage
The track shoe bolts are 22.0 mm (0.87 inch).
The torque requirement for track shoe bolts is
500 70 Nm (370 50 lb ft). Tighten the bolts by an
additional turn of 120 degrees.
Conventional Undercarriage
The track shoe bolts are 19.0 mm (0.75 inch).
The torque requirement for track shoe bolts is
400 70 Nm (300 50 lb ft). Tighten the bolts by an
additional turn of 120 degrees. If you are using bolts
with a master link, tighten the bolts to a torque of
400 70 Nm (300 50 lb ft). Then, tighten the bolts
by an additional turn of 180 degrees.
i01989298
Illustration 213
g01021588
Illustration 214
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138
Maintenance Section
Transmission Breather - Clean
Illustration 215
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Illustration 217
g00785460
Illustration 216
g01021583
Illustration 218
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139
Maintenance Section
Transmission Breather - Replace
i02403434
Illustration 219
g01198807
Transmission Scavenge
Screen - Clean
SMCS Code: 3030-070-MGS
When you change the transmission oil , clean the
scavenge screen.
Illustration 220
g01147719
See the Topic Transmission System Oil Filter Replace in this manual for the procedure to change
the filters.
140
Maintenance Section
Transmission System Oil - Change
SEBU7925-08
Illustration 222
g01198905
Illustration 221
g01147719
3. Fill the bevel gear case with oil. See Topic Refill
Capacities in this manual.
Illustration 223
g01147802
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141
Maintenance Section
Transmission System Oil Filter - Replace
i02400260
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Illustration 225
g01142953
Full marks
(5) Warm oil
(6) Cold oil
Illustration 224
g01198916
142
Maintenance Section
Transmission System Oil Level - Check
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Illustration 226
g01198905
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143
Maintenance Section
Trunnion Bearing - Adjust
i01499083
Illustration 227
g01198946
g00666217
g01143656
144
Maintenance Section
Winch Fairlead Rollers - Lubricate
SEBU7925-08
Illustration 230
g00292740
Typical example
Illustration 231
g01076211
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145
Maintenance Section
Winch Oil and Breather - Change/Clean
PA140VS
Illustration 232
g01076215
g01143124
146
Maintenance Section
Window Washer Reservoir - Fill
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i02284183
Wire Rope
Wire Rope
Diameter
Recommended
Ferrule
Holding Capacity
25 mm (1 inch)
J-8
91 m (300 ft)
29 mm
(1.13 inch)
J-9
84 m (276 ft)
32 mm
(1.25 inch)
J-10
59 m (193 ft)
Illustration 235
g01143289
Illustration 234
g00550538
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147
Maintenance Section
Windows - Clean
Illustration 237
g01143477
Rear window
g01143314
i02284774
Windows - Clean
SMCS Code: 7310-070; 7340-070
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.