Caterpillar D3K, D4K and D5K: Maintenance (Every 2000 Service Hours or 1 Year)

This includes the following types of coolants.

• Commercial long life coolants that meet the Caterpillar Engine Coolant Specification -1 (Caterpillar “EC−1”)

• Cat Diesel Engine Antifreeze/Coolant (DEAC)

• Commercial heavy-duty antifreeze/coolant

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

• Open the left engine access door.

• Open the access panel on top of the engine compartment.

• The cooling system pressure cap (1) is located on the top of expansion tank (2). Remove the cooling system pressure cap slowly in order to relieve system pressure.

• Obtain the coolant sample from the top tank and collect the sample into the proper sampling bottle.

Use the following guidelines for proper sampling of the coolant:

• Complete the information on the label for the sampling bottle before you begin to take the samples.

• Keep the unused sampling bottles stored in plastic bags.

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

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

• Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination.

• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.

• Maintain the coolant level between minimum mark (B) and maximum mark (A). Add coolant, if necessary.

• Install cooling system pressure cap (1) onto expansion tank (2). Close the access panel on top of the engine compartment. Close the left engine access door.

Final Drive Oil - Change

• Move the machine so that final drive oil level mark (3) is horizontal and final drive drain plug (1) is at the bottom of the final drive.

• Remove final drive drain plug (1) and allow the oil to drain into a suitable container.

• Clean drain plug (1) and replace the plug . Tighten the drain plug to a torque of 175 ± 15 N·m (130 ± 10 lb ft).

• Remove oil filler plug (2). Add oil until the oil is level with the plug threads. Refer to Operation and Maintenance Manual, “Lubricant Viscosities” and Operation and Maintenance Manual, “Capacities (Refill)”.

• Clean oil filler plug (2) and install the plug . Tighten the oil filler plug to a torque of 285 ± 30 N·m (210 ± 20 lb ft).

• Repeat this procedure for the other final drive.

• Install the hydraulic cap.

• Start the engine and run the engine for a few minutes.

• View the sight gauge through the slot above the rear access door on the back of the machine. Maintain the hydraulic oil level above the “ADD” mark (2) on the sight gauge. Add oil, if necessary.

• Open the right rear access door.

• View the sight gauge inside the right rear access door, if equipped. Maintain the hydraulic oil level above the “ADD” mark (2) on the sight gauge. Add oil, if necessary.

• Note: The oil must be free of bubbles. If bubbles are present in the oil, air is entering the hydraulic system. Inspect the suction hoses and the hose clamps.

• Stop the engine.

• If necessary, tighten any loose clamps and any loose connections. Replace any damaged hoses.

• Close the access door.

Winch Oil - Change

• Park the machine on level ground.

• Remove drain plug (1) and allow the oil to drain in a suitable container.

• Note: To help drain the oil, remove oil filler plug (2).

• Install plug (1) after all of the oil has been drained. Tighten plug (1) to a torque of 175 ± 15 N·m (130 ± 10 lb ft).

• Refill the winch to the proper level. Install plug (2).

Winch Vent Plug - Clean

• Remove the vent plug.

• Clean the vent plug in a suitable solvent.

• Install the vent plug.