SEBU5495-02

CATERPILLAR

D4E
Tractor-Type Tractor
76W1-Up
77W1-Up
27X1-Up
28X1-Up
29X1-Up
50X1-Up
51X1-Up
52X1-Up
68X1-Up
69X1-Up
. 70X1-Up
71X1-Up
72X1-Up
A IMPORTANT SAFETY NOT~CE
Periodic and proper lubrication and maintenance is important to
the safe and reliable operation of this machine. This Guide outlines
recommended procedures, some of which require the use of
special tools or work methods.
Improper lubrication and maintenance of this machine can be
dangerous and could result in injury or death.
READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND
WARNINGS BEFORE PERFORMING LUBRICATION OR MAINTENANCE
ON THIS MACHINE.
Basic safety precautions are outlined in the SAFETY section of this
Guide and in the description of operations where hazards exist.
Warning labels have also been put on the machine to provide
instructions and to identify specific hazards which if not heeded
could cause bodily injury or death to you or other persons. These
warnings in the Guide and on the machine labels are identified by
the symbol A
Operations that may result only in machine damage are identified
by CAUTION labels on the machine and in the Guide.
Caterpillar cannot anticipate every possible circumstance that
might involve a potential hazard. The warnings in this Guide and on
the machine are therefore not all inclusive. If a procedure, tool or
work method not specifically recommended by Caterpillar is used,
you must satisfy yourself that it is safe for you and others and the
machine will not be damaged or made unsafe by the procedures you
choose.

A WARNING
Perform all maintenance operations, unless otherwise specified, with all
equipment lowered, the transmission control lever in NEUTRAL, the
parking brake applied, the engine stopped and the electrical disconnect
key removed.
Do not operate this machine unless you have read and understand the
instructions in the "Operation Guide." Improper machine operation is
dangerous and could result in injury or death. The "Operation Guide" is
in a holder located in operator's compartment or on the seat back. Con-
tact any Caterpillar dealer for a replacement guide. Proper operation is
your responsibility.
 FOREWORD
This book is a guide to equipment care . The illustrated , step-by-step instructions
are grouped by servicing intervals; ite ms without specific intervals are listed under
"WHEN REQUIRED ". Circled numbers in the " LUBRICATION AND MAINTENANCE
CHART" are to key the charted items to the instructions in the book.

Use the service meter to determine se rvicing intervals. Calendar intervals (daily,
weekly, 2 weeks, etc .) shown may be used instead of service meter intervals if this
method provides more convenient servicing schedules; and approximates the indi-
cated service meter reading .
NOTE
Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in
the " LUBRICATION AND MAINTENANCE CHART" may be necessary.

Service Meter

Perform previous interval items at multiples of the original requirement. For ex-
ample, at " EVERY 100 SERVICE HOURS OR 2 WEEKS ", also perform those items
listed under " EVERY 50 SERVICE HOURS OR WEEKLY" and "EVERY 10 SERVICE
HOURS OR DAILY".

Some photographs in th is publication may show details or attachments that may

be different from your unit. Also, the ROPS (Roll Over Protection Structure) for some
photographs, may have been removed for illustrative purposes .

Continuing improvement and advancement of product design may cause changes

to your machine which may not be included in this publication . Each publication is
reviewed and rev ised , as required , to update and include these changes in later
editions .
 TABLE OF CONTENTS

Safety .............................................................................................................. 3
Maintenance Recommendations . ... . .. .. .. .. .... .. .. .. .. .. .. .. ... ... . ... . .. ... . .. .. ... .. .. .. .. .. ... ... . 5
Walk-Around Inspection ..................................................................................... 7
Coolant, Fuel and Lubricant Specifications ........................................................ 8
Lubrication and Maintenance Chart .. .. .. .. .... .. .. .. .. .. .. .... .. .. .. .. .. .. .. .... .. .. .. .. .. .. ... ... .. . 9
Every 10 Service Hours or Daily . .. .. .. ... .. ... .. .. ... .. .. .. .. .. . .. .. ... .. .. .. ... .. ... .. .. .. .. ... ... . 12
Every 50 Service Hours or Weekly ................................................................. 15
Every 100 Service Hours or 2 Weeks .. .. .. .. .. .. .. ... .. .. .... .. . ... .. .. .. .. .. .. .. .. .. .. ... .. .. .. 16
Every 250 Service Hours or Monthly .. .. .. .... . ... .. ... .. .. ... .. .. .. .. .. ... .. ... .. ... .. .. .. .. .... . 17
Every 500 Service Hours or 3 Months . ... .... .. .. .. .. ... .. ... .. .. ... . .. .. .. .... ... .. .. .. ... .. ... . 22
Every 1000 Service Hours or 6 Months . .... .. ... .. .. .. .. .. .. .. .. .. ... .. .. .. ... ... .. ... .. ... ... .. 28
Every 2000 Service Hours or 1 Year . .. ... .... .. .. .. .. ... .. .... . .. .. ... .. .. .. .... .. ... .. ... .. .... . 32
When Required .. .. .... .. .. .. .. ... .. .... .. .. .. ... .. .. .... .. ... ... . ... .. .... .. .. .. .. .. .. .. .. .. .. ... .. .. ... .. .. . 37
Refill Capacities . .. .... .. .. ... .. .. .. .... .. .. .. .. ... .. .... .. ... .. .. ... .. .... . .. ... .. .. .. .. .... .. ... .. .. ... .. .. . 51
G.E.T. Bolt Torques ............. ...... ..................................................................... 51
Serial Number Locations .. .. .. .. .. ... . ... .. .. .. .. .... ... .. .. .. .. ... ... .. .. ... .. .. .. .... .. ... ... . ... .. .... 52

2
I SAFETY I THIS SYMBOL WARNS OF POSSIBLE
PERSONAL INJURY

&,. WARNING
Before servicing the ma-
chine, lower all equip-
ment, stop engine and
lock parking brake, un-
less otherwise specified.

\
Block blade before changing
\,.

Use caution when removing ra-

cutting edge or end bits. diator cap, drain plugs, grease
fittings or pressure taps .

Attach tags to controls while Turn disconnect switch OFF and Read and understand warning
tractor is being serviced. remove key before serv icing and caution information provided
electrical system . on the tractor. Follow servicing
instructions carefully.

To avoid possible weakening of the ROPS (Roll-
over Protection Structure), consult a Caterp illar
dealer before altering the ROPS in any way. The
protection offered by the ROPS will be impaired
if it has been subjected to structural damage or
has been involved in an overturn incident.
Wear safety glasses and shoes as the job requires.
Operate engine only in well ventilated area.
Store oily rags or other combustible material in a
safe place.

When us ing pressure air wear safety glasses and Do not allow unauthorized personnel on tractor
protective clothing . Max imum air pressure must when it is be ing serviced.
be below 30 psi (205 kPa) .

Do not attempt repairs you do not understand .

3
 THIS SYMBOL WARNS OF POSSIBLE
PERSONAL INJURY
Do not attempt adjustments while tractor is moving
or the engine running.
Wear gloves when handling cable.
Do not use cable if it is kinked or frayed.
Do not try to work winch over capacity.
Do not smoke while refueling. Fumes from fuel
are flammable.
Whenever draining lubricant extreme caution
should be used, lubricant may be hot and can
cause personal injury.
Do not smoke when observing battery electrolyte
level. Batteries give off flammable fumes.
Do not allow electrolyte solution to contact skin
or eyes. Electrolyte solution is an acid.
Attach ground cable last, and remove first, to pre-
vent sparks from occurring near the battery, which
could cause battery vapors to explode. Attach
ground cable from booster battery to starter
ground terminal on machine to be started.
4
Hot hydraulic oil can cause personal injury. Re-
move hydraulic tank filler cap slowly to relieve
tank pressure. Allow oil to cool before draining
tank.
Hydraulic oil is flammable. Do not weld on pipes
or tubes that are filled with oil.
Always inspect cooling system with engine
stopped. Remove radiator filler cap slowly to re-
lieve pressure. Steam may cause personal injury.
Inhibitor contains alkali, avoid contact with skin
and eyes.
To prevent personal injury always lower all equip-
ment, stop engine, set parking brake and block
or restrain machine before servicing it.
If engine is not running, do not release emergency
or parking brake systems unless machine is
blocked or restrained.
 MAINTENANCE AECOM
. ' . · ,-. - ·.· ,_ ? . ·):"
COOLING
CAUTION
Never add coolant to an overheated engine; allow
engine to cool first.
Check specific gravity of antifreeze solution fre-
quently in cold weather to assure adequate
protection.
When permanent antifreeze and water solutions
are used in the cooling system, the solution should
be drained and replaced "EVERY 2000 SERVICE
HOURS OR 1 YEAR".
However, when additions of inhibitor are made
to the cooling system "EVERY 500 SERVICE
HOURS OR 3 MONTHS", it is not necessary to
drain and refill yearly. The antifreeze change period
can be extended to 4000 service hours or 2 years.
Do not use Caterpillar Corrosion Inhibitor with
Dowtherm 209 Coolant.
If machine is to be stored in, or shipped to, an
area w ith below freez ing temperatures ; the
cooling system must either be protected to the
lowest expected ambient temperature, or drained
completely.
NOTE
The engine cooling system is protected to -20°F (-29°C),
with permanent-type antifreeze, when shipped from the factory .
Use clean water that is low in scale forming min-
erals, not softened water. Add Caterpillar Corro-
sion Inhibitor or equivalent to the water to provide
corrosion protection. Follow the recommendations
on the container for the quantity required.
1 pint (.5 litre) of Caterpillar Cooling System In-
hibitor per 4 U.S. gallons (15 litres) of coolant
will give the 3% concentration .
Whenever draining and refilling cooling system,
always recheck the coolant level when the engine
reaches normal operating temperature.
Filling at over 5 U.S. gallons (19 litres) per minute
can cause air pockets in the cooling system.
Premix antifreeze solution to provide protection to
the lowest expected ambient temperature. Pure
undiluted antifreeze will freeze at - 10°F (- 23°C).
Operate with a thermostat in the cooling system all
year-round . Cooling system problems can arise
without a thermostat.
5
ELECTRICAL
CAUTION
When using jumper cables be sure to connect
in parallel: POSITIVE ( +) to POSITIVE ( + ) and
NEGATIVE ( - ) to NEGATIVE ( - ).
When using external electrical source to start ma-
chine, turn disconnect switch off and remove key
before attaching jumper cables.
HYDRAULIC
CAUTION
Make-up oil added to the hydraulic system must
mix with the oil already in the tank. Use only pe-
troleum products unless system is equipped for
use with special products.
Water or air can cause pump failure. If hydraulic
oil becomes cloudy, then water or air is entering
the system. Drain fluid, retighten hydraulic suc-
tion line clamps, purge and refill system. See your
Caterpillar dealer for purging instructions.
FUEL
CAUTION
Fill fuel tank at the end of each day of operation
to drive out moisture laden air and to prevent
condensation. Do not fill the tank to the brim. The
fuel expands when it gets warm and may overflow.
Check fuel level with dipstick in filler open ing.
Water and sediment shou ld be drained from the
fuel tank at the start of each shift or after the fuel
tank has been filled and allowed to stand for 5 to
10 minutes.
Drain fuel tank of moisture and sediment as re-
quired by prevailing conditions.
After changing fuel filters, always bleed fue l sys-
tem to remove air bubbles from system .
Drain water and sediment from the main fue l stor-
age tank weekly, and before the tank is refi lled.
This will help prevent water or sed iment from
being pumped from the st orage tank into the
machine fuel tank.
AIR INTAKE
Check precleaner screen dai ly for accumulation
of dust and debris.
Service air cleaners when RED band in ind icator
locks in visible position.
GENERAL
CAUTION
Accumulated grease and oil on a machine is a fire
hazard. Remove this debris with steam cleaning
or high pressure water, at least every 1000 hours
or each time any significant quantity of oil is spilled
on a machine.
CAUTION
When lubricating drive shaft universal joints, use
a lever-type hand-operated grease gun. Use of
pressure air operated lubricating equipment may
damage seals.
6
SCHEDULED OIL SAMPLING
Use Scheduled Oil Sampling to monitor machine
condition and maintenance requirements.
Each oil sample should be taken when the oil is
hot and well mixed to ensu re the sample is rep-
resentative of the oil in that compartment.
Consu lt your Caterpillar dealer for complete infor-
mation and assistance in establishing a Scheduled
Oil Sampling program for your equipment.
 For maintenance and operator personnel safety, and maximum service life of the machine, make a
thorough walk-around inspection when performing lubrication and maintenance work. Inspect under
and around the machine for such items as loose or missing bolts, trash buildup, oil, fuel or coolant leaks.

TRACK ENGINE COMPARTMENT

Inspect for broken Inspect for oil and
or missing shoes fuel leaks.
or bolts.

COOLING SYSTEM
SPROCKETS Inspect for leaks, worn
Inspect for wear. INDICATORS AND GAUGES
Inspect for damage. hoses, and trash buildup.

~..

TRANSMISSION AND
FINAL DRIVES ROLLERS IDLERS
Inspect for leaks. Inspect for wear Inspect for wear
or leaks. and leaks.

HYDRAULIC SYSTEM COVERS AND GUARDS

Inspect for leaks, worn Inspect for damage, loose
hoses or damaged lines. or missing bolts.

7
Coolant, Fuel and Lubricant Specifications

I~

Coolant Specifications Fuel Specifications

CAUTION Types of Fuel
Use a mixture of water, ethylene glycol (antifreeze)
and cooling system conditioner. Pure, undiluted
antifreeze will freeze at - 23° C ( -10° F).
Caterpillar diesel engines have the ability to burn
a wide variety of fuels. These fuels are divided into
Do not use Caterpillar liquid cooling system condi- two general groups, preferred and permissible.
tioner or coolant conditioner elements with Dow-
therm 209 Full-Fill coolant. Follow the instructions The preferred fuels provide maximum engine
provided with the Dowtherm 209 Full-Fill coolant. service life and performance. They are distillate
fuels. They are commonly called diesel fuel, fur-
Refer to "Know Your Cooling System," Form
nace oil, gas oil or kerosene.
SEBD0518, for more detailed specifications.
The permissible fuels are crude oils or blended
Water fuels. Use of these fuels can result in higher mainte-
nance costs and reduced engine service life.
Acceptable water for use in the ethylene glycol
and water mixture is shown in the chart below: Refer to "Fuels for Caterpillar Diesel Engines,"
Form SEHS7067, for a detailed summary of pre-
Acceptable Water
ferred and permissible fuels and their specifica-
50% Antifreeze Without tions.
Water Content 50% Water Antifreeze
Chlorides
100 ppm 50 ppm Refer to S.A.E. J313 Diesel Fuels for informa-
or less or less tion about better quality fuels, such as ignition
100 ppm 50 ppm quality, gravity I density, viscosity, cloud point, sul-
Sulfates
or less or less
fur content, etc.
Hardness as 200 ppm 100 ppm
CaCo3 or less or less
Fuel Sulfur Content
500 ppm 250 ppm
Dissolved Solids
or less or less The percentage of sulfur in the fuel will affect the
pH 6.5 or higher 6.5 or higher engine oil recommendations. If the fuel has over
ppm = parts per million 0.5% sulfur content, the engine oil must have a
Antifreeze TBN of 20 times the percentage of fuel sulfur (TBN
as measured by the ASTM D-2896 method). If the
Use the correct amount of ethylene glycol mixed sulfur content is greater than 1.5%, consult your
with water, to provide freeze protection to the Caterpillar dealer for correct engine oil recommen-
lowest expected outside temperature. dations.
Fuel sulfur is chemically changed during com-
Conditioner bustion to form sulfuric acid. The acid chemically
CAUTION attacks metal surfaces and causes corrosive
Always add liquid cooling system conditioner to wear. Higher engine oil TBN values are essential to
water, or install a coolant conditioner element (if minimize corrosive wear.
equipped). Never use water only.
Periodically request fuel sulfur content informa-
Never use both liquid cooling system conditioner
and a coolant conditioner element (if equipped) at tion from your fuel supplier. Fuel sulfur content can
the same time. change with each bulk delivery.

Use Caterpillar liquid cooling system conditioner Fuel Cetane Requirement

or a coolant conditioner element (if equipped). This I~
will provide a 3% to 6% concentration of condition- The minimum fuel cetane number recommended
er in the cooling system to help prevent corrosion. for the direct injection engine is 40.

Conditioner can be purchased from your The minimum fuel cetane number recommended
Caterpillar dealer. for the precombustion engine is 35.
8
Fuel Cloud Point
Fuel waxing can plug the fuel filters in cold
weather. The fuel cloud point must be below the
temperature of the surrounding air to prevent filter
waxing and power loss. Fuel heating attachments
are available from your Caterpillar dealer to mini-
mize fuel filter waxing.
Lubricant Specifications
Power Train System Oil - Transmission,
Torque Converter and Clutch Oil
{CD/T0-2)
Use Service Classification CD oils that have
satisfactory performance in the Caterpillar Oil Test
Number T0-2. These oils are referred to as Ser-
vice Classification CD I T0-2 oils.

The abbreviations listed below follow S.A.E. Hydraulic Oils {HYDO)

J754 nomenclature. The classifications follow
S.A.E. J 183 classifications. The MIL specifica-
tions are U.S.A. Military Specifications. These def-
initions will be of assistance in purchasing lubri-
cants. The recommended oil viscosities are found
on the "Recommended Lubricant Viscosities"
chart.
Use Engine Service Classification CC (MIL-L-
21048), CC/SF (MIL-L-461528), CD (MIL-L-
2104D) or industrial-type hydraulic oils that are
certified by the oil supplier to have antiwear, anti-
foam, antirust, and antioxidation additive proper-
ties for heavy duty use.

The prefix "SPC" is a general abbreviation used Multipurpose-type Gear Lubricant

by Caterpillar to identify special oils such as syn- {MPL)
thetic or semi-synthetic oils.
Use Gear Lubricant Classification GL-5 (MIL-L-
Engine Oils {CD or CD/T0-2) 21058).

Use oils that meet the Engine Service Classifica- Lubricating Grease {MPG)
tion CD (MIL-L-2104D) or CD/T0-2.
Use Multipurpose-type Grease (MPG). Multipur-
Consult the ''EMA Lubricating Oils Data Book,''
pose-type greasewhich contains 3% to 5% molyb-
Form SEBU5939, for a listing of CD oil brands.
denum disulfide (MPGM) is preferred. NLGI No. 2
The percentage of sulfur in the fuel will affect the Grade is suitable for most temperatures. Use NLGI
engine oil recommendations. If the fuel has over No. 1 or No. 0 Grade for extremely low tempera-
0.5% sulfur content, the CD engine oil must have a tures.
TBN of 20 times the percentage of fuel sulfur (TBN
as measured by the ASTM D-2896 method). If the
sulfur content is greater than 1.5%, consult your
Caterpillar dealer for correct engine oil recommen-
dations.
Higher TBN values are essential to retard the
corrosive damage to metal engine parts.
Your oil supplier should be able to furnish the
correct oils.

BA
Coolant, Fuel and Lubricant Specifications

Recommended Lubricant Viscosities

For Use At Outside Temperatures From -30°C (-22°F) to + 50°C ( + 122°F)*

Outside °C -30 -20 -10 0 + 10 +20 +30 + 40 + 50
Temperature °F -22 - 4 + 14 +32 +so +68 + 86 +104 +1 22

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'4V"'""' IW• 1r111M·•ao 1b ±tilt *
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Engine I I I
CD
or
CD/T0-2 I I I I I I
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SPC"' SAE6W·20

Power Train I I
Oil System,
Winch I I
CD/T0-2
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SPC"' SAE5W·20
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HYDO ,,
SM' ~ "' 4'.'J $!¥
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Final Drive
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cc.co I I
or I I
CD/T0-2
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Outside °C -30 - 20 - 10 o + 10 +20 + 30 + 40 + 50

Temperature °F - 22 - 4 + 14 +32 + 50 + 68 + 86 + 104 + 122
'When operating below - 30 °C ( - 22 ° F) refer to the Cold Weather Operation Guide, Form SEBU5338, available from your
Caterpillar dealer.

88
LUBRICATION AND MAINTENANCE CHART

® Engine Crankcase
Observe coolant level
Measure oil level CD
• 12
12
® Precleaner
©Fuel Tank
Inspect - clean if necessary
Drain water and sediment
•• 13
13
® Water Separator Drain water
• 13

® Bulldozer Cylinder Support and Lubricate 6 fittings MPG 15

Upper Trunnion Bearings
CJ) Ripper Linkage Lubricate l 2 fittings MPG 15
@ Track Roller Frame Inner Bearings Lubricate 2 fittings MPG 15
@ Track Roller Frame Outer Bearings Lubricate 2 fittings MPG 15
@) Flexible Coupling Grease Seal Lubricate l fitting MPG 15
(Power Shift)
@Winch Observe oil level CD/T0-2 15
Do Item @after first 50 service hours on new or reconditioned power shift transmission equipped
machines only.

@ Operator's Seat (Special Application only)

@ Hydraulic Control System Observe oil level HYDO 16
@Batteries - Inspect low maintenance high outpu
(LMHO) batteries at the Every 250 Service Hours or
Monthly interval
Inspect electrolyte level -
clean terminals, and top of
batteries
• 16

Do Item @after first 100 service hours on new or reconditioned machine.

@ Bulldozer Blade Tilt Ball and Socket Lubricate 2 fittings MPG 17

(4S only)
@ Fan Bearing Lubricate 1 fitting MPG 17
@ Fan and Alternator Belts
@Brakes
Inspect - adjust if necessary
Inspect - adjust if necessary
•• 17
17
@ Transmission and Torque Converter Change filter element CD/T0-2 18
(Power Shift)
@ Transmission (Direct Drive) Measure oil level CD/T0-2 19

9
LUBRICATION AND MAINTENANCE CHART

@Track Adjust track

• 19
@ Air Conditioner Observe sight glass - test
for proper function • 21

For Direct Injection Engines only , change oil, filter and wash breather at this interval. See page 22 for procedure.

Inspect the Low Maintenance High Output Battery at this interval. See page 16 for procedure.

@ Engine Crankcase Change oil,m filter and CD 22

wash breather

® Hydraulic Control System Change filter HYDO 23

@ Fuel Tank Cap and Screen Clean
• 24
@
@
Cooling System
Steering Booster System (Direct Drive)
Add corrosion inhibitor
Change filter element and CD/T0-2
• 24
25
wash screen

@
@
Winch Breather
Winch Oil Sump
Change breather
Change oil and wash strainer CD
• 28
28
@ Universal Joint and Clutch Brake Lubricate 3 fittings MPG 28
(Direct Drive)
@ Final Drives Change lubricant CC or C 28
@ Transmission and Torque Converter Change oil,< 2> breather and CD/T0-2 29
(Power Shift) wash suction screen
@ Bevel Gear, Steering Clutch Compartment Change oi1,< 2> and breather CD/T0-2 30
and Steering Booster System
(Direct Drive and Power Shift)
@ Flywheel Clutch Breather Change breather
• 31

@ Engine Valve Lash Inspect - adjust if necessary

• 32
@ Hydraulic System (Power Shift
and Direct Drive)
Change oil - wash filler and
strainer - inspect suction
hoses and clamps
• 32

@ Cooling System Change antifreeze solution

• 33
@ Transmission (Direct Drive) Change oil and breather CD/T0-2
• 34
@ Flywheel Clutch (Direct Drive) Change oil and wash screen
• 35
@ Sprocket Hub Bearing Inspect adjustment if sprocket
is loose or leakage develops
or is suspected
• 36

m The percentage of sulfur in the fuel will affect the engine oil recom-
mendations. If the fuel has over 0.5% sulfur content, the CD engine
oil must have a TBN of 20 times the percentage of fuel sulfur (TBN
as measured by the ASTM D-2896 method). Your oil supplier
should be able to furnish the correct oils.

mchange oil any time it becomes thick and dork.

10
LUBRICATION AND MAINTENANCE CHART

@Track If track was adjusted when

sprocket teeth were clean -
readjust if packing is
• 37

present
@ Final Drive Inspect lubricant level if CC or CD 37
leakage develops or is
suspected
@Seat Belt Inspect - replace if damaged.
Seat belt must be replaced at
least every 3 years
• 38

@ Transmission {All Machines) Inspect lubricant level if CD/T0-2 38

leakage develops or is
suspected
@Fuses Replace fuses if elements are
broken - reset breaker • 38

@Winch Inspect lubricant level if

leakage develops or is
suspected. Replace cable if
• 39

@ Engine Air Intake System
it is kinked or frayed
Clean when RED band in
indicator locks in visible
position
• 40

@ Fuel System Change filter when fuel gauge

registers OUT with engine
running
• 43

@Cooling System Drain and clean when engine

overheats or solution is dirty • 44

@) Cooling System Relief Cap Clean or replace if engine

overheats or coolant loss
is observed
• 45

® Cutting Edges and End Bits Change cutting edge and use
new end bits if worn • 46

@ Ripper - Tip Replacement Change ripper tip if damaged

or worn • 46

@ Bulldozer Ball and Socket Inspect adjustment if brace

is too loose or too tight • 47

@Fuel Tank
@ Flywheel Clutch and Brake
Drain anytime engine misfires
Adjust clutch if slippage is
•• 47
48
{Direct Drive) observed - adjust clutch brake
@) Water Separator Change element if frozen, dirty
or torn • 49

®
@
Air Conditioner
Flywheel Clutch Compartment
Wash filter elements
Inspect lubricant level if CD/T0-2
• 50
50
(Direct Drive} leakage develops or is
suspected
@) Bevel Gear and Steering Clutch Inspect lubricant level if CD/T0-2 50
Compartment (Power Shift and leakage develops or is
Direct Drive) suspected

11
.EVERY 10 SERVICE HOURS OR DAILY I
G)RADIATOR

A WARNING
Always inspect cooling system with en-
gine stopped.

Remove filler cap slowly to relieve pres-

sure. Steam can cause personal iniury.

Inhibitor contains alkali, avoid contact

with skin and eyes to prevent personal
iniury.

NOTE
If it is necessary to add coolant daily, inspect cooling system 1. Remove filler cap slowly to relieve pressure.
for leaks. Observe coolant level. Inspect cap gasket and
replace if necessary.

®ENGINE CRANKCASE

Park machine on level ground, lower all equip-

ment, engage parking brake.

1. Measure oil level.

2. Maintain coolant level within 1/2 inch (1 cm) 2. Engine stopped: Maintain oil level in the SAFE
of bottom of fill pipe. Install filler cap. STARTING RANGE on the ENGINE STOPPED
side of dipstick, with oil cold.

3. Engine Running : Maintain oil leve l between 4. Add oil if necessary.

ADD and FULL marks on the ENGINE RUNNING
side of dipstick, with engine at low idle and oil NOTE
warm. Do not overfill crankcase with oil.

12
(DPRECLEANER
& WARNING

Service air cleaner with engine stopped.

Inspect for dirt accumulation . Remove and empty

bowl when dust accumulation reaches line.

G)FUEL TANK

Periodically remove and wash entire precleaner 1. Open drain valve and drain off any sediment
assembly in water. or water that may have accumulated .

@WATER SEPARATOR (If Equipped)

Observe water separator and drain any water

before starting engine .
2. Close drain valve .
Anytime the water separator becomes 1/2 full of
NOTE water, stop the engine and drain separator.
If no water or sediment is present, drain interval may be
extended. NOTE
Change element anytime water separator becomes contam·
inated enough that water level cannot be seen through the
transparent cover.

13
.EVERY 10 SERVICE HOURS OR DAILY

2. Close drain and vent valves.

1. Open vent valve (A) and drain

valve (8) and allow water to
drain .

14
 EVERY 50 SERVICE HOURS OR WEEKLY
@BULLDOZER CYLINDER SUPPORT (J) RIPPER LINKAGE
AND UPPER TRUNNION BEARINGS

Lubricate 3 fittings on each side of tractor. Total 6 Lubricate 12 fittings .

fittings.

@TRACK ROLLER FRAME INNER @TRACK ROLLER FRAME OUTER

BEARINGS BEARINGS

Lubricate 1 fitting on each roller frame. Total 2 Lubricate 1 fitting on each side of tractor. Total 2
fittings . fittings .

@)FLEXIBLE COUPLING GREASE @WINCH

SEAL (Power Shift}

Lubricate 1 fitting on left side of tractor. With engine running at low idle, observe oil level.
Oil should be visible in sight gauge.

Add oil if necessary.

15
 EVERY 100 SERVICE HOURS OR 2 WEEKS
@OPERATOR'S SEAT @HYDRAULIC CONTROL SYSTEM
(SPECIAL APPLICATION)

~I
Lubricate 9 fittings on seat suspension under seat . Observe oil level with equipment lowered, engine
running at low idle, transmission in NEUTRAL and
brake engaged and locked. Oil should be visible
in sight gauge.
@BATTERIES

/!J. WARNING
Batteries give off flammable fumes that
can explode. Do not smoke when observing
electrolyte level.

Electrolyte is an acid and can cause per-

sonal injury if it contacts skin or eyes.

1. Open access door.

3. Maintain electrolyte level to bottom of fill plug

openings. At proper charging rate, batteries will
not require more than 1 ounce (30 cc) of water per
cell per week.

4. Close access door.

2. Clean top of batteries . Keep terminals clean

and coated with petroleum jelly.

16
 EVERY 250 SERVICE HOURS OR MONTHLY
@)BULLDOZER BLADE TILT BRACE @FAN BEARING
BALL AND SOCKET
(SS BULLDOZER)

'.<~"'"*

,; ) )

Lubricate 1 fitting on each brace. Total 2 fittings. Lubricate 1 fitting for fan drive.

.,,.
@FAN AND ALTERNATOR BELTS
~-----~

.,t.
\•
l
·1
1. Inspect condition of belts. 2. Apply 25 lb (11.5 kg) pres- 3. Loosen mounting and bracket
Always install a matched set if sure midway between pulleys. bolt and move alternator, as re-
either belt needs replacing . Deflection should be 718 inch quired, to adjust belts. Tighten
(22 mm). bolt .
@BRAKES To Adjust:

Check adjustment. Adjust brakes
when pedal travel reaches 6
inches (15.0 cm).
1. Remove guard and cover.
'"'_.
\
2. Turn adjusting screw in until
tight. Back screw out (counter-
clockwise) 2-1 / 2 turns or until
pedal has approximately 3 inches
free travel.

17
I. EVERY 250 SERVICE HOURS OR MONTHLY
@)TRANSMISSION AND TORQUE
CONVERTER - (Power Shift)
& WARNING

Hot oil or components can cause per-

sonal injury if they contact skin. Use
caution when draining oil or changing
filters.

Park machine on level ground, equipment low- 1. If machine is equipped with a decelerator, re-
ered, parking brake applied, and engine OFF. move two bolts that hold the decelerator assembly
to floor plate. Remove floor plate.

2. Remove bolts for the filter cover and filter 4. Remove the retaining nut from the stud . Re-
assembly. move the used filter. Clean cover.
3. Remove the filter assembly. 5. Inspect condition of cover seals. Replace seals
if used ones are damaged.

6. Install a new filter and retaining nut. 7. Install cover and filter assembly. Install cover
bolts .

18
 NOTE
Measure oil level, with engine at low idle,
transmission in NEUTRAL and parking
brake engaged and locked.

8. Open access door. 9. Oil level must be between A DD

and FULL marks on dipstick, add
oil if necessary.

@)TRANSMISSION (Direct Drive)

NOTE
Measure oil level with engine at low idle,
transmission in NEUTRAL and parking 3. Close access door.
brake engaged and locked.

1. Open access door. 2. Maintain o il level to between

ADD and FULL marks on dip-
stick. Add o il if necessary.

@TRACK - Adjustment

NOTE
Tracks should be adjusted under the same conditions in which
the machine will be used. If packing conditions prevail on the
job, the tracks should be adjusted with packing present .

Run the tractor in the forward d irection at least CAUTION

twice the length of the tractor, then al low tractor Do not attempt to adjust track when stop on adjust-
to coast to a stop. Do not brake tractor to stop it. ing rod is within 5.1 inches (130 mm) (A) of stop
on roller frame. Contact your Caterpillar dealer
for track service.

19
·EVERY 250 SERVICE HOURS OR MONTHLY
$ ef
'-"., _
1. Raise inspection plate and add MPG through
fill valve until idler moves forward and track is
tight.
3. Be sure there is space for front idler to retract .
Raise inspection plate.
4. Open relief valve and allow the idler to move
back. Moving the machine in REVERSE will help
move the idler back.
20
------ ~
~-·
2. Make a mark on the roller frame 3 / 8 in (10
mm) behind the idler bearing support on machines
that have one carrier roller on each side .
Make a mark on the roller frame 1I 2 in ( 13 mm)
behind the idler bearing support on machines that
have two carrier rollers (extended under carriage)
on each side.
A WARNING
Never visually inspect relief valve to see
if grease is escaping. Always observe
the track to see if it has loosened.
Loosen relief valve one turn only.
5. Close relief valve.
l v} NOTE
Contact your Caterpillar dealer if correct adjustment cannot
be obtained.
~ ---

·~~\
6. Add MPG through fill valve until mark on roller
frame is aligned with rear edges of idler bearing
support.

@AIR CONDITIONER
__.,.....

1. Start and run engine at high idle.
2. Set air conditioner controls for maximum cold,
and blower on HIGH. Allow 2 minutes for system
to stabilize.
3. Observe sight glass, in ceiling of cab under
plug cover. If bubbles are present , turn air
conditioner OFF.

5. If poor cooling is experienced turn the air

conditioner off.

6. Stop engine.

7. Contact your Caterpillar dealer for air condi-

tioner system service, if necessary.

4. If no bubbles are present in sight glass, feel

suction line (A) and discharge line (8). The dis-
charge line should be warmer than the suction
line.

21
. EVERY 500 SERVICE HOURS OR 3 MONTHS

@ENGINE CRANKCASE

A WARNING
Hot oil on components
can cause personal in-
jury if they contact skin.
Use caution when drain-
ing oil or changing filters. \

Run engine long enough to warm 1. Open drain valve and allow 2. Use a strap wrench to remove
oil. oil to drain . used filter element.

3. Apply a thin coat of clean engine oil to the

gasket of the new filter.
NOTE
The filters may have rotation index marks spaced 90° apart.
These marks should be used when tightening the new filter
an additional 3/4 turn more.

4. Install filter element by hand . Tighten until

gasket contacts base. Tighten filter an additional
3/ 4 turn more.
CAUTION
DO NOT OVERTIGHTEN

6. Inspect seal, install new seal if necessary.

Install breather. Tighten bolt to 10 + 2 lb. ft.
(14 + 3 N ·m).

7. Fill crankcase . See REFILL CAPACITIES .

8. Start engine and run at low idle to fill filter

housing. Check for leaks.

9. Install breather and mounting bolt . Reconnect

·"' n · ifijf JJ! hose and tighten hose clamp .

5. Loosen hose clamp and remove hose from

breather. Remove breather mounting bolt and
remove breather.

22
@HYDRAULIC CONTROL SYSTEM
&_WARNING

Hot oil or components can cause per-

sonal injury if they contact skin. Use
caution when draining oil or changing
filters.

Park engine on level ground, lower all equipment, 1. Loosen tank filler cap slowly to relieve pressure.
engage parking brake, and shut engine OFF.

2. Remove bleed screw in bottom of filter hous- 3. Unscrew filter housing mounting stud from
ing and drain housing. base. Remove filter housing and filter element.

4. Clean filter base and inspect condition of seal. 5. Clean the filter housing . Install a new filter
Replace seal if used one is damaged . element in the housing.

23
I. EVERY 500 SERVICE HOURS OR 3 MONTHS

7. Start and run engine at low

idle.

6. Install the filter housing and 8. Observe oil level in sight

element on the filter base. gauge. Add oil if necessary.

9. Install hydraulic tank filler

@FUEL TANK CAP AND SCREEN cap.

,,,
~-

1. Remove fuel tank filler cap. Disassemble cap 3. Remove screen retaining ring , dipstick and
and wash in clean non-flammable solvent. filler screen .

2. Oil elements slightly and assemble cap. 4. Wash screen in clean non-flammable solvent.

@COOLING SYSTEM
(Add Corrosion Inhibitor)

A WARNING

Always inspect coolinp system with en-

5. Install screen and retaining ring .
6. Install dipstick and filler cap.
gine stopped.
Remove filler cap slowly to relieve pres-
sure. Steam can cause personal injury.
Inhibitor contains alkali, avoid contact
with skin and eyes to prevent personal
injury.

24
 CAUTION
Do not use Caterpillar Corrosion Inhibitor with
Dowtherm 209 coolant.

At first 500 SERVICE HOURS OR 3 MONTHS on

a new or reconditioned machine: Add enough
Caterpillar Corrosion Inhibitor, or equivalent, so
that the cooling system will have a 3% concen-
tration of inhibitor.
NOTE
Add 2 pints (1 litre) of inhibitor to this cooling system.

EVERY 500 SERVICE HOURS, OR 3 MONTHS

thereafter: Add 1 pint (.50 litre) of Caterpillar Corro-
sion Inhibitor, or equivalent to this cooling system . 1. Loosen filler cap slowly to relieve pressure.
This will maintain the required 3% concentration Remove cap.
of inhibitor.
@STEERING BOOSTER SYSTEM
(Direct Drive)
NOTE
It may be necessary to drain enough coolant to allow for the &,_WARNING
addition of corrosion inhibitor.

2. Add Caterpillar Corrosion Inhibitor. See above
for amount of inhibitor to add.
3. Observe condition of filler cap gasket. Replace
is used one is damaged.
Hot oil or components can cause per-
sonal injury if they contact skin. Use
caution when draining oil or changing
filters.

4. Install radiator filler cap.

Park machine on level ground, lower equipment,

apply parking brake , and shut engine off.

Filter

1. Remove floor plate . 2. Remove filter cover bolts. Remove filter cover.

25
EVERY 500 SERVICE HOURS OR 3 MONTHS

I
3. Inspect condition of cover seals. Replace seals 4. Remove filter from housing .
if used seals are damaged.
5. Install a new filter.

Strainer

6. Install cover and cover bolts. 7. Remove cover from the strainer.

8. Remove the strainer.

9. Wash strainer in clean non-flammable solvent.

10. Install strainer and cover.

26
11 . Install floor plate.
NOTE
Measure oil level with transmission in NEUTRAL, brake en-
gaged and locked and flywheel clutch engaged.

12. Start and run engine at low idle.

13. Open access door. Maintain oil level between

ADD and FULL marks on dipstick.

14. Add oil if necessary.

15. Close access door.

27
 EVERY 1000 SERVICE HOURS OR 6 MONTHS

@WINCH BREATHER @)WINCH OIL SUMP

&_WARNING

Hot oil or components can

cause personal injury if
they contact skin. Use
caution when draining oil
or changing filters.

1 . Remove and discard breather. Park machine, on level ground , 1. Remove drain plug and fill
Install a new breather. lower equipment, apply parking plug. Allow oil to drain.
brake and shut engine off.
2. Clean and install drain plug.

6. Fill compartment until oil is

visible in the sight gauge. See
4. Wash the strainer in clean REFILL CAPACITIES. Clean and
non-flammable solvent. install fill plug .

5. Install strainer and strainer 7. Start and run engine at low

cover. idle. Observe oil level with en-
gine running at low idle. Oil level
must be visible in sight gauge.

3. Remove strainer cover. Re-

move the strainer.

@)UNIVERSAL JOINT AND CLUTCH BRAKE @FINAL DRIVES

(Direct Drive)
&_WARNING

Hot oil or components can

cause personal injury if
they contact skin. Use
caution when draining oil
or changing filters.

1. Remove floor plate. Lubricate 2. Lubricate 1 fitting for the fly- Park machine on level ground,
2 fittings for the universal joints. wheel clutch brake assembly . equipment lowered, parking brake
Total 3 fittings. applied and engine OFF.

3. Install floor plate .

28
 \.,.;.-

3. Clean and install drain plugs.

4. Fill compartments with oil. See

REFILL CAPACITIES.

5. Clean and install fill plugs.

1. Remove final drive fill plug 2. Remove drain plug on each

on each side. side and allow oil to drain.

@TRANSMISSION AND TORQUE CONVERTER (Power Shift}

IA WARNING
Hot oil or components can
cause personal iniury if
they contact skin. Use
caution when draining oil
or changing filters.

Park machine on level ground, 1. Remove transmission drain 2. Remove cover housing spring
equipment lowered parking brake plug and allow oil to drain. and screen.
applied and engine OFF.

3. Remove nut on stud and sep- 4. Inspect cover gasket. Install 5. Install screen, spring and hous-
arate cover, housing, spring and new cover gasket if necessary. ing to cover. Be sure pin on
screen. Wash screen in clean screen is aligned with hole in
solvent. cover. Install nut on stud.

29
 EVERY 1000 SERVICE HOURS OR 6 MON·THS

9. Open right side access door.

6. Install screen assembly. 10. Remove fill plug.

7. Install transmission and torque 11. Fill compartment with oil.

converter drain plug. See REFILL CAPACITIES.

12 . Observe oil level with en-

gine running at low idle and
transmission in NEUTRAL.

~ 13. Add oil if necessary. Install

8. Remove breather and install fill plug.
new breather.

@BEVEL GEAR, STEERING CLUTCH COMPARTMENT AND STEERING

BOOSTER SYSTEM (Direct Drive & Power Shift)

A WARNING
Hot oil or components can cause per-
sonal injury if they contact skin. Use
caution when draining oil or changing
filters.

Park machine on level ground, lower all equipment, 1 . Remove 3 drain plugs from the bevel gear and
engage parking brake, and shut engine OFF. steering clutch compartment. Allow oil to drain.

2. Clean and install drain plugs .

3. Remove breather. Install a new breather. 4. Open access door. Fill compartment with oil.
See REFILL CAPACITIES.

5. Measure oil level, add oil if necessary.

30
@FLYWHEEL CLUTCH
BREATHER

Remove and discard breather.

Install a new breather.

31
 EVERY 2000 SERVICE HOURS OR 1 YEAR .

@ ENGINE VALVE LASH

NOTE
Adjust valves with engine stopped and cold.
EXHAUST VALVES .025 inch (0.64 mm)

NOTE
F If valve clearance is within ± .003 inch (.076 mm) of t he
L nominal clearance given, adjustment is not required. If clear-
y ance is not within these limits adjust the valves.
w
H Use Caterpillar part number 5P7307 engine turn-
E ing tool to turn engine. See 04 E TRACK TYPE
E
L TRACTOR SERVICE MANUAL FOR VA LV E
A DJUSTMENT PROCEDURE.
INLET VALVES .015 inch (0 .38 mm)

Measure valve lash with engine stopped .

CAUTION
Do not u~e starter to rotate crankshaft. Rotat e in direction of normal rotation.

@HYDRAULIC CONTROL SYSTEM

/!::,.WARNING

Hot oil or components can cause per-

sonal injury if they contact skin. Use
caution when draining oil or changing /
~/

filters.

--; ;/
•
Park machine on level ground, lower all equ ipment, 1. Remove hydraulic tank fill cap. Inspect filler cap
engage parking brake, and shut engine OFF. gasket. Replace gasket if used gasket is damaged.

2. Remove strai ner. Wash strainer in clean non- 3. Remove tank drain plug and allow oil to drain .
flammable solvent. Install strainer. Clean and install drain plug.

32
 NOTE
Measure oil level with engine at low idle, transmission in
NEUTRAL and brake engaged and locked. Oil level must be
~-
between ADD and FULL marks on dipstick.
I·

~
5. Recheck oil level. Oil should be visible in sight
gauge.

6. Add oil, if required , to bring oil to correct level.

7. Inspect suction hoses and clamps of hydraulic
control system. Replace cracked or swollen hoses.
Retighten clamps or replace flange gasket if tight-
ening does not stop leakage.

4. Fill hydraulic tank. See REFILL CAPACITIES .

@COOLING SYSTEM - Changing Antifreeze Solution

A WARNING
Always inspect cooling system with en-
gine stopped.
Remove filler cap slowly to relieve pres-
sure. Steam can cause personal injury.
Inhibitor contains alkali, avoid contact
with skin and eyes to prevent personal
injury.
CAUTION
If machine is to be stored in, or shipped to, an
area with below freezing temperatures; the
cooling system must either be protected to the
lowest expected ambient temperature, or drained
completely.
When permanent antifreeze and water solutions
are used in the cooling system, the solution should
be drained and replaced "EVERY 2000 SERVICE
HOURS OR 1 YEAR."
However, when additions of inhibitor are made
to the cooling system "EVERY 500 SERVICE
HOURS OR 3 MONTHS ", it is not necessary to
drain and refill yearly . The antifreeze change
period can be extended to 4000 service hours
or 2 years.
CAUTION
Do not use Caterpillar Corrosion Inhibitor with
Dowtherm 209.
NOTE
Add 1 pint (.5 litre) Caterpillar Corrosion Inhibitor, or equiva-
lent, per 4 U.S. Gallons (15 litres) of coolant to give a 3%
concentration of corrosion inhibitor to the cooling system.

33
 EVERY 2000 SERVICE HOURS OR 1 YEAR ·
1. Loosen filler cap slowly to release pressure,
and remove cap.
3. Close coolant drain valve. Install drain valve
plug.
4. Mix antifreeze solution to provide protection to
the lowest expected ambient temperature.
NOTE
Do not completely fill cooling system. Allow for addition of
Caterpillar Corrosion Inhibitor, or equivalent, so that the
cooling system will have a 3% concentration of inhibitor.
@TRANSMISSION (Direct Drive)
/n,. WARNING
Hot oil or components can cause per-
sonal injury If they contact skin. Use
caution when draining oil or changing
filters.
Park .machine on level ground, equipment lowered,
parking brake applied and engine OFF.
34
"\
2. Remove cooling system drain valve plug, open
valve and allow coolant to drain .
5. To help avoid air locks, add coolant slowly,
at 5 U.S. gallons (19 litres) per minute or less, to
within 1/2 inch (1 cm) of bottom of fill pipe.
6. Add antifreeze solution. See REFILL CAPAC-
ITIES . Add 2 pts. (1 ltr.) of Caterpillar Corrosion
Inhibitor or equivalent.
7. Start and run engine with filler cap removed .
Allow coolant to warm and level to stabilize. Add
coolant if necessary. Stop engine.
8. Inspect filler cap gasket. Replace if damaged.
Install filler cap.
1. Remove drain plug and allow oil to drain .
2. Clean and install drain plug .
 @FLYWHEEL CLUTCH
(Direct Drive)
&, WARNING
Hot oil or components can cause per-
sonal injury if they contact skin. Use
caution when draining oil or changing
filters.

3. Open access door. Fill transmission with oil. Park machine on level ground, lower all equipment,
See REFILL CAPACITIES. engage parking brake, and shut engine OFF.

4. Close access door.

1. Remove drain plugs from flywheel clutch . 2. Remove suction screen cover and screen .

3. Wash screen in clean non-flammable solvent.

4. Clean and install drain plugs.

5. Install suction screen and cover.

6. Fill flywheel clutch with oil. See REFILL

CAPACITIES.

35
EVERY 2000 SERVICE HOURS OR 1 YEAR

@SPROCKET HUB BEARING

1. Remove guards. 2. Place a 5 foot (1.5 m) bar be- 3. Pry on bar. If sprocket side
tween the track roller frame and movement is noticeable, contact
the sprocket. your Caterpillar dealer.

36
 WHEN REQUIRED

@TRACK

If track was adjusted with sprocket teeth clean - NOTE

readjust track if packing in the sprocket tooth area Tracks should be adjusted under the same conditions in which
the machine will be used. If packing conditions prevail on the
is present. job, the tracks should be adjusted with packing present.

See TRACK - ADJUSTMENT in EVERY 250

SERVICE HOURS or MONTHLY.

&_WARNING

Never visually inspect relief valve to see

if grease is escaping. Always observe
the track to see if it has loosened.

Loosen relief valve one turn only.

CAUTION
Do not attempt to tighten track when stop on
adjusting rod is within .125 inches (3.2 mm), @,
of stop on roller frame.Contact your Caterpillar
dealer for track service.

@FINAL DRIVE

..
1. Remove fill plug . 2. Check oil level. Maintain oil to bottom of plug
opening. Clean and install fill plug.

37
 -WHEN REQUIRED

@SEAT BELT
&, WARNING
Seat belt must be replaced every 3 years
regardless of appearance.

Inspect seat belt and counting hardware. Replace

any damaged components.

Inspect seat belt and all hardware.

@TRANSMISSION (Direct ~rive and Power Shift}

NOTE
Inspect lubricant level if leakage develops or is suspected.

am
Check oil level with engine at low idle, and trans-
mission in NEUTRAL. Maintain oil level at FULL
mark on gauge.

@FUSES

1. When electrical circuits do not function remove 2. Reset circuit breaker if it has opened.
and inspect fuses. Replace any fuse which has a
broken element.

38
@WINCH

NOTE
Make certain winch mounting bolts are secure and no oil leak-
age is observed.

Measure oil level with engine at low idle, trans-

mission in NEUTRAL and brake engaged and
locked. Maintain oil level between ADD and FULL
marks on dipstick.
Drum Drag

Drum drag can be increased or decreased by

turning drum drag lever.

Cable Installation

Do not underwind cable onto winch drum.

NOTE
Cable overwind is standard. Winch cannot be modified for underwind operation.

Cable is attached to the drum with a standard cable ferrule. The ferrule, is fitted into a socket on the
drum and secured with a bolt-down clamp.

When ordering cable from your local supplier, use the following guide to specify the correct ferrule.

CABLE CABLE FERRULES DRUM CABLE CAPACITY

DIAMETER* DIAMETER LENGTH STANDARD
IN. MM NUMBER IN. MM IN. MM FT. M
3/4 19 86 1-5/8 41 2 51 168 51.2
NOTE
If cable diameter is increased from the standard diameter it should be done for extended cable life only. •tis not to be used
for increasing winch pulling capacity.

39
 WHEN REQUIRED
Put the cable in a straight line behind the tractor. Remove bolt
groove G). Install clamp ®and bolt
@ENGINE AIR INTAKE SYSTEM
Servicing Primary Element
&WARNING
Service air cleaner with
engine stopped.
2. Remove primary element.
l\
CD and clamp ® · Install cable end into
CD.
Service elements if RED band 1. Remove cover of air cleaner
in indicator is locked up. Stop housing .
engine.
NOTE
The primary element should be replaced
after being cleaned a maximum of 6
times. Replace the element once a year
even though it has not been cleaned
6 times.
4. Clean and inspect element .
Install clean element.
CAUTION
Always inspect primary element
before and after cleaning with a
3. Clean inside of air cleaner light bulb inside element. ,Dis-
body. Clean cover. card if any tears, rips or damage
is evident.
40
 - ......

NOTE
If indicator shows RED shortly after in-
stallation of a primary element, which
has been cleaned approximately 6 times,
change to another clean element.

If indicator still shows RED after the in-

stallation of the clean primary element,
change the secondary element.

5. Install cover. Tighten cover 6. Reset indicator.

bolts to a torque of 3 lb. ft .
(4 N·m).

Servicing Secondary Element CAUTION

Always replace the secondary element. Do not attempt to reuse by cleaning.
NOTE
Replace the secondary element at the time the primary element is cleaned for the third time.

1 . Remove cover and primary element. 2. Remove secondary element.

3. Inspect condition of seal be-

tween air cleaner housing and
intake manifold.

4. Cover air inlet opening.

7. Tighten retaining bolt nuts to
5. Clean air cleaner body, un- 20 + 5 lb. ft. (25 + 7 N·m).
cover air inlet.

6. Install new secondary element.

41
WHEN REQUIRED I
- - ......._I

,. \
NOTE
If indicator still shows RED after instala-
tion of new secondary elements, install
other clean primary elements.

5. Install primary element and 9. Reset indicator.

cover.
Cleaning Air Cleaner
Elements Pressure Air - 30 psi (205 kPa) Maximum
/n. WARNING
When using pressure air,
wear safety face shield
and protective clothing.
Use 30 psi C205 kPal
maximum pressure air
for cleaning purposes.

CAUTION
Do not clean elements by bump-
ing or tapping.
Do not use elements with dam- 1. Direct air inside element 2. Direct air outside element
aged pleats, gaskets or seals. along length of pleats. along length of pleats. Direct air
NOTE
inside element along length of
Have spare elements on hand to use pleats . Inspect element.
while cleaning used elements.

Water - 40 psi (280 kPa) Maximum Detergent

1. Direct water inside element 2. Direct water outside element 1. Wash element in warm water
along length of pleats. along length of pleats. Rinse, air and non-sudsing household
dry thoroughly and inspect. detergent.

42
 Inspecting Element

2. Rinse with clean water, see

above .

3. Air dry thoroughly and inspect

element.

1. Insert light inside clean and 2. Wrap and store good ele-
dry element and inspect. Dis- ments in a clean, dry place.
card element if rips or tears are
found .

@FUEL SYSTEM
Filter

Change filter element when fuel 1. Stop engine. Close fuel supply 2. Remove filter element with
pressure gauge registers OUT valve. strap wrench.
with engine running .

5. Install new element by hand.

6. When gasket contacts filter

base, tighten 3/4 turn more.

7. Open fuel supply valve .

8. Prime the fuel system .

3. Clean filter base. Make sure 4. Coat gasket of new element

all of old gasket is removed. with clean diesel fuel.

43
 WHEN REQUIRED

Priming Fuel System

3. When fuel flows free of bubbles

close pump and lock plunger.

4. Close bleed valve.

5. Start engine and check for

leaks.

1. Open fuel system bleed valve. 2. Unlock priming pump plunger

and operate pump.

@COOLING SYSTEM - Cleaning

&_WARNING

Always inspect cooling system with en-

gine stopped.
Remove filler cap slowly to relieve pres-
sure. Steam can cause personal injury.
Jnhibitor contains alkali, avoid contact
with skin and eyes to prevent personal
injury.
CAUTION
If machine is to be stored in, or shipped to, an
area with below freezing temperatures, the
cooling system must either be protected to the
lowest expected ambient temperature, or drained
completely.
Do not use Caterpillar Corrosion Inhibitor with
Dowtherm 209.

CAUTION
Never add coolant to an overheated engine, allow
engine to cool first.

Machine level, engine stopped and cool.

1. Loosen filler cap slowly to relieve pressure, 2. Open drain valve and allow coolant to drain.
and remove filler cap.

44
 7. Start and run engine for 10 minutes. Stop en-
&_WARNING gine and drain neutralizing solution.

Use all cleaning solutions with care.

8. Flush system with clean water, until draining

NOTE water is clean. Do not run engine while flushing.
Most commercial cooling system cleaners may be used.

9. Close drain valve.

3. Close drain valve . Fill system with cleaning
solution.m
10. Install access plate.
4. Start and run engine for 1/2 hour. Stop engine
and drain cleaning solution. 11 . Mix antifreeze solution to provide protection
to the lowest expected ambient temperature.
5. Flush system with clean water until draininq
water is clean. Do not run engine while flushing . NOTE
Do not completely fill cooling system. Allow for addition of
6. Close drain valve. Fill system with neutralizin Caterpillar Corrosion Inhibitor, or equivalent.
solution.m

12. To help avoid air locks, add coolant slowly, 16. Add coolant, if necessary, to bring level to
at 5 U.S. gallons (19 litres) per minute or less. bottom of fill pipe.

13. Add antifreeze solution . See REFILL

CAPACITIES.
14. Add 2-1/2 pints (1.4 litres) of Caterpillar Corro-
sion Inhibitor, or equivalent, so that this cooling
system will have a 3% concentration of inhibitor.
17. Observe condition of filler cap gasket. Re-
place if damaged. Install filler cap.
m2 lb. Sodium Blsulfate (NaHSO.) per 10 U.S. gallons (1 kilo-
gram per 40 litres) water.

15. Start and run engine with filler cap removed. <2>1/2 lb. Sodium Carbonate Crystals (Na2COa • 10 H20) per
Allow coolant to warm and level to stabilize. 10 U.S. gallons (250 grams per 40 litres) water.

@COOLING SYSTEM RELIEF CAP

&_WARNING

Always inspect cooling system with en-

gine stopped.

Remove filler cap slowly to relieve pres-

sure. Steam can cause personal injury.

Inhibitor contains alkali, avoid contact

with skin and eyes to prevent personal
injury.

Clean or replace relief cap when cooling system

does not maintain pressure, or coolant loss is
experienced.

/
45
 WHEN REQUIRED
@CUTIING EDGE AND END BITS
Change cutting edge, and use new end bits, before wear starts on blade support.

' ILP

1. Raise and block blade before 2. Remove bolts. 3. Remove cutting edge or bit.
changing cutting edge or end Clean contact surfaces.
bits.

6. Install bolts and tighten to spec-

ified torque. See G.E.T. BOLT
TORQUE CHART.

7. After a few hours of operation

retighten bolts to proper torque.

4. Use opposite cutting edge if 5. Use new end bit.

not worn. Use new section if both
edges are worn .

@RIPPER - Tip Replacement

&,_WARNING

To avoid possible injury to eyes, wear safety glasses when striking pins. The pin, when
struck, can fly out and cause injury to nearby personnel.

1. Drive pin out and remove tip. 2. Check plug . Metal part of plug 3. Install tip in either digger or
must be toward pin hole. runner position. Align pin holes
and install pin .
46
@)BULLDOZER - Diagonal Arm and Tilt Brace Ball and Socket Adjustment

1. Remove cap bolts. Shorten
brace and remove shims.
2. Clean grease from ball and
socket. Clean shims.
3. Lengthen brake . Install and
tighten bolts evenly.
4. Measure clearance between
cap and socket with shims .
5. Remove bolts and shorten
brace. Install shims equal to
measured clearance plus 1 shim.
6. Lengthen brace and install
bolts . Tighten bolts to 150 + 20
lb. ft . (205 + 25 N·m). Lubricate
ball and socket.

@FUEL TANK

Open drain valve and drain off any sediment or 1. Remove fuel tank filler cap. Disassemble cap
water that may have accumulated . Close valve. and wash cap in clean solvent. Examine filler
cap gasket and replace if damaged.

2. Oil elements lightly and assemble cap. Install

~p. /

47
 ·WHEN REQUIRED
@FLYWHEEL CLUTCH
CAUTION
Measure and make adjustment
with the engine stopped and the
clutch cold.
A properly adjusted clutch will
require a clutch lever pull or ap-
proximately 220 to 270 N.m
( 162 to 200 lb.ft.) Slightly more
effort may be required if the
clutch is warm.
Clutch Brake
With engine running, push the
clutch control lever forward .
If the clutch shaft is slow in
stopping, adjust brake.
4 .. .. turn adjusting rod unt il
brake lining con tacts drum
evenly.
To Adjust:
.·•.!...Ii
)
1. Remove floor plate and clutch 4. Turn flywheel 180° and loosen
inspection cover. Turn flywheel other locknut.
until one of the locknuts is
visible. 5 . Turn adjusting ring to obtain
correct adjustment.
2. Loosen locknut 2 turns.
6. Tighten locknuts to 30 lb. ft.
3. Tap plate to be sure it is free (40 N·m).
on stud.
7. Install inspection cover.
1. Remove floor plate. 3. Hold control lever forward
and . ..
2. Loosen locknut on lever
linkage.
5. Release control lever and
turn adjusting rod in (clockwise) CAUTION
2 turns. Do not adjust brake too tight.
6. T ighten locknut and install Difficult shifting and rapid brake
floor plate. lining wear will result.
7. Start eng ine and test brake.
48
@WATER SEPARATOR (If Equipped) - Installing New Element

Install new element when holes 1. Close fuel supply valve. 2. Open vent valve.
become clogged with sediment.

\
~l

I 1~1 <~J. '

3. Open drain valve and allow 5. Remove dirt and debris from 6. Push face of clamp and lift up
water to drain from element. between clamp and element. on top of clamp.

4. Close drain and vent valves . 7. Remove clamp and discard

element and 0-rings.

11. Open fuel supply valve.

8. Clean water separator base. 9. Install new 0-rings and lubri-

cate 0-rings. Install element.

10. Install clamp .

49
 ·WHEN REQUIRED
@AIR CONDITIONER - Cleaning Elements
Fresh Air Filters

1. Open cover and remove filter elements. 2. Clean elements by using pressure air or by
tapping element on a smooth object.

3. Install element.
Recirculating Filter

1. Remove cover and remove filter element. 2. Clean element with pressure air or wash ele-
ment in warm water and a non-sudsing household
detergent, rinse in clean water and air dry
thoroughly. Install element and cover.

@FLYWHEEL CLUTCH COMPARTMENT @)BEVEL GEAR AND STEERING

(Direct Drive) CLUTCH COMPARTMENTS

1. Measure oil level. 1. Measure oil level.

2. Add oil if necessary. 2. Add oil if necessary.

50
REFILL CAPACITIES (Approximate) I

COMPARTMENT OR U.S. METRIC IMPERIAL

SYSTEM MEASURE MEASURE MEASURE
Engine Crankcase 5 gal. 19 litres 4 gal.
Transmission, (Direct Drive) 2.25 gal. 9 litres 2 gal.
Final Drives (each) 2.5 gal. 9 litres 2 gal.
Hydraulic System 6 gal. 22 litres 5 gal.
Cooling System 9 .5 gal. 35.75 litres 8 .0 gal.
Fuel Tank 50 gal. 19 0 litres 42 gal.
Winch 7.5 gal. 28.4 litres 6 .25 gal.
Flywheel Clutch (Direct Drive) 2.25 gal. 9 litres 2 gal.
Bevel Gear. Steering Clutch
Compartment and Steering Booster
System 18 gal. 68.25 litres 15 gal.
Bevel Gear and Steering Clutch
Compartment 16.5 gal. 61.25 litres 13.75 gal.
Transmission and Torque Converter
(Power Shift) 10.5 gal. 39.75 litres 8.5 gal.

.
BOLT SIZE RECOMMENDED TORQUE*
Inch mm lb ft N·m
518 16 195±25 265 ± 34
3/4 19 350± 50 470 ± 70
718 . 22 565 ±85 770 ± 115
1 25 900±110 1220 ± 150
"These values are appllcable only to Caterplllar plow bolta.

51
SERIAL NUMBER LOCATIONS I

) ..
• ,~.,
v •
COMBINATION PLATE BEVEL GEAR CASE ENGINE

---"'I

rr :., * - .~··A4
BULLDOZER RIPPER HYDRAULIC CONTROL

WINCH

52
 ,.

..

. .....

SEBU5495-02 (1-84) CATERPILLAR. CAT anti CB are trademarks of Caterpillar Inc. Printed in U.S.A.