Manufacturing / Industrial • Maintenance

Caterpillar D3K, D4K and D5K: Maintenance (When Required)

This service maintenance procedure focuses on air filter compartment, ground level service, pump compartment, capsule filte, etc. This procedure will help you maintain superior efficiency of your equipment.

MaintainX

10/24/2021

Caterpillar D3K, D4K and D5K: Maintenance (When Required)

Backup Alarm - Test

Turn the engine start switch to the ON position in order to perform the test.
Apply the decel/brake pedal. Disengage the parking brake switch. Move the transmission control lever to the REVERSE position.

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

Illustration 111

The backup alarm is on the rear of the machine.

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

Battery - Inspect

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

Open the battery access cover.
Clean the top of the batteries with a clean cloth. Keep the terminals clean and coated with petroleum jelly. Install the terminal covers after you coat the terminals.
Close the battery access cover.

Battery - Recycle

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the following locations:

A battery supplier
An authorized battery collection facility
Recycling facility

Battery or Battery Cable - Inspect/Replace

! WARNING

Personal injury may occur from failure to properly service the batteries.

Batteries give off flammable fumes that can ex- plode. Electrolyte is an acid and can cause per- sonal injury if it contacts the skin or eyes.

Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jumper ca- ble ends to contact each other or the engine. Im- proper jumper cable connections can cause an ex- plosion.

Illustration 112

Illustration 113

Illustration 114

Belt - Inspect/Replace

Inspect

Park the machine on level ground. Lower the dozer blade to the ground. Move the transmission control to the NEUTRAL position and engage the parking brake. Shut off the engine.
Open the engine enclosure.
Inspect the condition of the serpentine belt (1) for any of the following conditions: • excessive cracking • excessive wear • excessive damage The belt deflection should not be more than 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.
Note: The deflection of the serpentine belt has the same limit with an alternator only.
Note: This machine is equipped with one belt tensioner (2). The belt tensioner automatically adjusts the belt to the correct position.
Close the engine enclosure.

Replace: Contact your Caterpillar dealer in order to replace the belt, if necessary.

Brakes, Indicators and Gauges - Test

Check the operation of the Caterpillar Monitoring System. Observe the self test when you start the engine.

The system performs an automatic self test when you turn the engine start switch to the ON position.

The self test verifies that the monitoring panel and the display modules are operating properly.

The internal circuits, the indicators, and the gauges are automatically checked.

The operator must observe whether gauges (1), indicators (2), and displays (3) are operating properly. The self test lasts for approximately three seconds.

During the self test, all alert indicators flash.

The digital display shows the following readouts:

All indicators of units (Deg C, kPa, rpm, and liters)
“X10” readout
Symbol for the hour meter
“8.8.8.X.8.8” readout
The pointers in the gauges point upward. Then, the pointers point to the left. Then, the pointers point to the right. Then, the pointers point to the final positions.
The action light stays illuminated.
The action alarm sounds once for one second.

The monitoring panel is then in the normal operating mode.

If the above tests are not correctly completed, the system will not function in the normal operating mode. Consult your Caterpillar dealer for an electrical system check. Any repairs must be made before you start the engine.

Braking System (Test)

! WARNING

If the machine moves during the test, reduce the engine speed immediately, and engage the parking brake.

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

Braking System (Test)

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.

Bulldozer Power Angling Tilt Hinge Pins - Lubricate

Apply lubricant to the grease fitting for the head end of the tilt cylinder (1).
Apply lubricant to the grease fitting for the rod end of the tilt cylinder (2).
Apply lubricant to the grease fitting for the rod end of the angle cylinder (3). Repeat for the left and right side angle cylinders.
Apply lubricant to the grease fitting for the head end of the angle cylinder (4). Repeat for the left and right side angle cylinders.
Apply lubricant to the grease fitting for the pivot pin on the main C-frame (5). Repeat for the left and right side angle cylinders.
Apply lubricant to the grease fitting for the rod end of the lift cylinder (6). Repeat for the left and right side lift cylinders.
Apply lubricant to the grease fitting for the head end of the lift cylinder (7). Repeat for the left and right side lift cylinders.
Apply lubricant to the grease fittings for the pitch link

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

Note: Clean the filter element more often in dusty conditions. If there is a noticeable reduction in the air flow from the air vents, check the filter element.

Open the access cover for the filter on the left side of the machine.
Remove filter element (1). Clean the filter element with compressed air.
Note: Do not clean the filter elements while the filter elements are installed on the machine.
Note: Do not wash the filter element with water.
Note: Keep the filter element dry.
Install the filter element. Install the access cover.

Cab Filter (Recirculation) - Clean/Inspect/Replace

Note: Clean the filter element more often in dusty conditions. If there is a noticeable reduction in the air flow from the air vents, check the filter element.
Remove filter element (1). The filter element is located next to the seat on the left side. Clean the filter element with compressed air.
Note: Do not clean the filter element while the filter element is installed on the machine.
Note: Do not use water in order to clean the filter element.
Note: The filter must be thoroughly dried before you install the filter.
Replace any filter element that is worn or damaged.
Install the filter element and replace the filter cover.
Note: Install the filter element with the filter media toward the inside of the cavity.

Circuit Breakers - Reset

The main circuit breaker is located in the front of the right console behind the cover plate.

Illustration 123. Front View

Illustration 124

Repair the fins if found defective.

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

Engine Air Filter Primary Element - Clean/Replace

NOTICE: Caterpillar recommends certified air filter cleaning ser- vices that are available at Caterpillar dealers. The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt to clean the filter element:

Do not tap or strike the filter element in order to remove dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove the dust from the filter element. Air pressure must not exceed 207 kPa (30 psi). Direct the air flow up the pleats and down the pleats from the inside of the filter element. Take extreme care in order to avoid damage to the pleats.
Do not use air filters with damaged pleats, gaskets, or seals. Dirt entering the engine will cause damage to engine components.

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

Loosen the four cover latches and remove the air cleaner cover.

Remove primary filter element (3) from air cleaner housing (2). In order to remove the engine air filter primary element, slide the element outward. While you pull the element outward, rock the element.

NOTICE Do not use a filter if the media, the gaskets or the seals are damaged.

Install clean primary filter element (3) over engine air filter secondary element (4). Apply firm pressure to the end of the primary element as you gently rock the filter element. This seats the primary element.

Clean cover (5) and install the cover.

Close the left engine access door.

Start the engine. The indicator on the gauge cluster will illuminate when the filter needs attention.

Cleaning Primary Air Filter Elements

The primary air filter element can be used up to three times if the element is properly cleaned and properly inspected. When the primary air filter element is cleaned, check for rips or tears in the filter material. The primary air filter element should be replaced at least one time per two year period. This replacement should be performed regardless of the number of cleanings.

NOTICE: Do not clean the air filter elements by bumping or tap- ping. This could damage the seals. Do not use ele- ments with damaged pleats, gaskets, or seals. Dam- aged elements will allow dirt to pass through. Engine damage could result.

Visually inspect the primary air filter elements before cleaning. Inspect the air filter elements for damage to the seal, the gaskets, and the outer cover. Discard any damaged air filter elements.

Pressurized air is the best method to clean primary air filter elements.

Engine Air Filter Secondary Element - Replace

NOTICE: Always replace the secondary element. Do not at- tempt to reuse it by cleaning. Engine damage could result.

Note: Replace the secondary filter element when you service the primary element for the third time. If a clean primary element has been installed and the filter element indicator still enters the red zone, replace the secondary filter element. Also if the exhaust smoke remains black and a clean primary filter element has been installed, replace the secondary filter element.

Steps:

Open the left engine access door.
Remove the housing cover to the precleaner body assembly.
Remove the secondary element. The secondary element is on the end of the air cleaner group away from the cab.
Cover the air inlet opening. Clean the inside of the air cleaner housing.
Inspect the gasket between the air inlet and the housing. If the gasket is damaged, replace the element.
Uncover the air inlet opening. Install a new secondary element.
Reinstall the primary air filter element.
Install the air cleaner housing cover.
Close the engine access door.

Illustration 138

Engine Air Precleaner - Clean

Open the left engine access cover.

Inspect the engine air precleaner for dirt and for trash.

Unscrew M6 allen head screw (1) in order to remove the integrated precleaner body (2) completely.

Use pressurized 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.

Loosen hard deposits of dust on the precleaner body by soaking in an appropriate cleaning agent. Then, wash the precleaner body with a spray of water.
Blow dry the precleaner body completely.

Install precleaner body (2) into the engine air precleaner. Latch the precleaner body in place.

Install allen head screw (1). Tighten the allen head screw to 6 ± 2 N·m (5 ± 1 lb ft) only.

Close the left engine access door.

NOTICE: Service the air cleaner only with the engine stopped. Engine damage could result.

Ether Starting Aid Cylinder - Replace

Open the engine access door on the left side of the machine.
Loosen the cylinder retaining clamp. Unscrew the empty ether starting aid cylinder and remove the empty ether starting aid cylinder.
Remove the used gasket. Install the new gasket that is provided with each new ether starting aid cylinder.
Install the new ether starting aid cylinder. Tighten the ether starting aid cylinder hand tight. Tighten the cylinder retaining clamp securely.
Close the engine access door.

Free Spool Drag - Adjust

Adjust the free spool drag to the operator's preference. For the correct procedure to adjust the free spool drag, refer to Specifications, Systems Operation, Testing and Adjusting, Disassembly and Assembly, “Free Spool - Test” for the winch hydrostatic systems.

Fuel System - Prime

! WARNING

Personal injury or death may result from failure to adhere to the following procedures.

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

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

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

! WARNING

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fu- el spray may cause a fire hazard. Failure to fol- low these inspection, maintenance and service in- structions may cause personal injury or death.

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

Fuel System Water Separator - Drain

! WARNING

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 when changing fuel filters or water separator elements. Clean up fuel spills immediately.

NOTICE: Ensure that the engine is stopped before any servicing or repair is performed.

NOTICE: The water separator can be under suction during nor- mal engine operation. Ensure that the drain valve is tightened securely to help prevent air from entering the fuel system.

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

Fuel Tank Cap - Clean

Fuel tank cap (1) is located on the left side on the rear of the machine.

Clean fuel tank cap (1) and the surrounding area.
Remove the fuel tank cap and disassemble the fuel tank cap.
Inspect the seal for damage. Replace the seal, if necessary. Lubricate the seal on the fuel tank cap.
Replace the element on the fuel tank cap.
Assemble the fuel tank cap and install fuel tank cap (1).

Fuses - Replace

Fuses – Fuses protect the electrical system from damage that is caused by overloaded circuits. Replace the fuse if the element separates. If the element of a new fuse separates, check the circuit. Repair the circuit, if necessary.

NOTICE: Replace the fuses with the same type and size only. Otherwise, electrical damage can result.

If it is necessary to replace fuses frequently, an electri- cal problem may exist. Contact your Caterpillar dealer

Note: The fuse panel for this machine is equipped with all of the available options.

The fuse panel is located on the front panel next to the right side of the seat.

Fuse Block 1

Oil Filter - Inspect

Inspect A Used Filter for Debris

Ilustration 189

Use a 4C-5084 Filter Cutter to cut the filter element open. Spread apart the pleats and inspect the element for metal and for other debris. An excessive amount of debris in the filter element can indicate a possible failure.

If metals are found in the filter element, a magnet can be used to differentiate between ferrous metals and nonferrous metals.

Ferrous metals can indicate wear on steel parts and on cast iron parts.

Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings, rod bearings, or turbocharger bearings.

Small amounts of debris may be found in the filter element. This could be caused by friction and by normal wear. Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found.

Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings, to the crankshaft, and to other parts. This can result in larger particles in unfiltered oil. The particles could enter the lubricating system and the particles could cause damage.

Radiator Core - Clean

Inspect the radiator for these items: damaged fins, corrosion, dirt, grease, insects, leaves, oil, and other debris. Clean the radiator, if necessary.

Illustration 190

Illustration 191

You can use compressed air, high pressure water, or steam to remove dust and other debris from the radiator core. However, the use of compressed air is preferred.

Inspect the radiator for these items: damaged fins, corrosion, dirt, grease, insects, leaves, oil, and other debris. Clean the radiator, if necessary.

Radiator Pressure Cap - Clean/Replace

Open the access panel on top of the engine compartment.
Slowly loosen pressure cap (1) in order to release pressure from the cooling system.
Remove the pressure cap.
Inspect the pressure cap for damage, for deposits, or for foreign material. Clean the pressure cap with a clean cloth. Replace the pressure cap if the cap is damaged.
Install the pressure cap.

Winch Cable - Replace

! WARNING

Wear leather gloves when handling the winch cable.

NOTICE: Unroll the wire rope cable from the spool. Never lift the wire rope off the spool in coils.

NOTICE: Use the correct size ferrule for the winch cable in order to attach the winch cable to the load drum. Never use a knot in order to secure the winch cable to the load drum.

TABLE 15

TABLE 16

Window Washer Reservoir - Fill

NOTICE: When operating in freezing temperatures, use Caterpillar or any commercially available nonfreezing window washer solvent.

Illustration 216

Illustration 217

Window Washer – Open the access door on the left side of the machine. Open the fluid bottle cap in order to fill the washer fluid bottle. Maintain the level in the washer fluid bottle between the maximum mark and the minimum marks.

Window Wipers - Inspect/Replace

Illustration 218

Inspect the front window wiper blade, the right window wiper blade, the left window wiper blade, and the rear window wiper blade. Replace any wiper blades that are damaged or worn. Replace any wiper blades that streak the window.

Windows - Clean

Illustration 219

Use commercially available window cleaning solutions to clean the windows.

Source: Caterpillar (www.pdfmanual4trucks.com)

Backup Alarm - Test

Backup Alarm - Test

Turn the engine start switch to the ON position in order to perform the test.

Apply the decel/brake pedal. Disengage the parking brake switch. Move the transmission control lever to the REVERSE position.

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

Illustration 111

The backup alarm is on the rear of the machine.

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

Battery - Inspect

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

Open the battery access cover.

Clean the top of the batteries with a clean cloth. Keep the terminals clean and coated with petroleum jelly. Install the terminal covers after you coat the terminals.

Close the battery access cover.

Battery - Recycle

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the following locations:

A battery supplier

An authorized battery collection facility

Recycling facility

Battery or Battery Cable - Inspect/Replace

! WARNING

Personal injury may occur from failure to properly service the batteries.

Batteries give off flammable fumes that can ex- plode. Electrolyte is an acid and can cause per- sonal injury if it contacts the skin or eyes.

Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jumper ca- ble ends to contact each other or the engine. Im- proper jumper cable connections can cause an ex- plosion.

Always wear protective glasses when working with batteries.

Turn the engine start switch key OFF. Turn all of the switches OFF.

Turn the battery disconnect switch OFF. Remove the key.

Disconnect the negative battery cable from the disconnect switch.

Note: Do not allow the disconnected battery cable to contact the disconnect switch.

Disconnect the negative battery cable at battery (1). The primary battery is located behind the right side access door.

Disconnect the positive battery cable at the battery.

Remove the mat and the floorplate in the cab in order to access the secondary battery. Perform steps 4 and 5 in order to disconnect the secondary battery.

Inspect the battery terminals for corrosion. Inspect the battery cables for wear or damage.

Make any necessary repairs. If necessary, replace the battery cables or the batteries.

Note: Replace the secondary battery carrier (strap) when the battery is replaced. Do not exceed a change interval of 48 months when the secondary battery carrier (strap) is replaced.

Connect the positive battery cable to the battery positive terminals.

Connect the negative battery cable to the battery negative terminals.

Connect the battery cable at the battery disconnect switch.

Install the key and turn the battery disconnect switch ON.

Illustration 112

Illustration 113

Illustration 114

Belt - Inspect/Replace

Inspect

Park the machine on level ground. Lower the dozer blade to the ground. Move the transmission control to the NEUTRAL position and engage the parking brake. Shut off the engine.

Open the engine enclosure.

Note: The deflection of the serpentine belt has the same limit with an alternator only.

Note: This machine is equipped with one belt tensioner (2). The belt tensioner automatically adjusts the belt to the correct position.

Close the engine enclosure.

Replace: Contact your Caterpillar dealer in order to replace the belt, if necessary.

Brakes, Indicators and Gauges - Test

Check the operation of the Caterpillar Monitoring System. Observe the self test when you start the engine.

The system performs an automatic self test when you turn the engine start switch to the ON position.

The self test verifies that the monitoring panel and the display modules are operating properly.

The internal circuits, the indicators, and the gauges are automatically checked.

The operator must observe whether gauges (1), indicators (2), and displays (3) are operating properly. The self test lasts for approximately three seconds.

During the self test, all alert indicators flash.

The digital display shows the following readouts:

All indicators of units (Deg C, kPa, rpm, and liters)

“X10” readout

Symbol for the hour meter

“8.8.8.X.8.8” readout

The pointers in the gauges point upward. Then, the pointers point to the left. Then, the pointers point to the right. Then, the pointers point to the final positions.

The action light stays illuminated.

The action alarm sounds once for one second.

The monitoring panel is then in the normal operating mode.

If the above tests are not correctly completed, the system will not function in the normal operating mode. Consult your Caterpillar dealer for an electrical system check. Any repairs must be made before you start the engine.

Braking System (Test)

! WARNING

If the machine moves during the test, reduce the engine speed immediately, and engage the parking brake.

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

Braking System (Test)

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.

Test:

Start the engine (1)

Raise all attachments (2)

Fully depress decel/brake pedal (5)

Release parking brake switch (3)