Caterpillar D3K, D4K and D5K: Maintenance (Every 50 Service Hours or Weekly)

Note: Enclosed ROPS only

• 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.

Check

• Park the machine on a hard, flat surface.

• Raise the blade to three inches off the ground.

• Move the machine in reverse until a track shoe grouser is directly below the center of the front idler shaft.

• Measure the height (A) from the flat ground surface to the grouser tip that is centered below the track idler shaft.

• Maintain the grouser height (rise) to the following dimensions. a. (A) Front Idlers Minimum – 0.5 mm (0 inch) Maximum – 4 mm (0.160 inch)

Adjust

• If the grouser height is not acceptable, add shims to the lower shim pack.

• Add shims to the upper shim pack. Make sure that a gap is spaced between the bearing block and the upper shim pack. 2 mm (0.080 inch) to 4 mm (0.160 inch)

• Measure the gap between the side shims and the idler block.

• Add shims to both side shim packs until the total amount of gap is between 4 mm (0.160 inch) and 8 mm (0.320 inch).

If the machine performance remains unacceptable after the shim adjustments, try the following steps.

• If the ride is unsatisfactory or short about the length of the track pitch scalloped edges appear. Then, the idler may be too low. Move a 2.3 mm (0.090 inch) shim from the bottom shim pack to the top. This happens during grading with an adequate link pitch (track pitch length).

• If the balance is poor or the balance is long about half the machine length, scalloped edges appear. Then, the idler may be too high. Move a 2.3 mm (0.090 inch) shim from the top shim pack to the bottom.

Moving the Top Shims

• Remove the track shoe directly in front of the top him pack.

• Remove the rock guards from the front track idler.

• Raise the machine so the idler is off the ground.

• Lower the machine so the first track roller or the second roller rests on a block and the idler remains in the air.

• Unscrew the bolts that hold the top shims.

• Remove a shim or add a shim.

• Replace the bolts that hold the shims. Torque the M12 bolts to 100 ± 20 N·m (75 ± 15 lb ft).

Moving the Bottom Shims

• Remove the track shoe directly in front of the bottom shim pack.

• Raise the machine so the idler is off the ground.

• Lower the machine so the idler rests on a block.

• Unscrew the bolts that hold the bottom shims.

• Remove a shim or add a shim.

• Replace the bolts that hold the shims. Torque the M12 bolts to 100 ± 20 N·m (75 ± 15 lb ft).

Reassembly

• Replace the idler guards. Torque the M12 bolts to 100 ± 20 N·m (75 ± 15 lb ft).

• Replace the track shoes. Torque the track shoe bolts for the D3K and D4K and D5K Track-Type Tractors.

• D3K and D4K Track-Type Tractors with SALT track – 90 ± 20 N·m (65 ± 15 lb ft)

• D5K Track-Type Tractor with SALT track – 170 ± 40 N·m (125 ± 30 lb ft)

• D3K and D4K Track-Type Tractors with SystemOne track – 145 ± 40 N·m (105 ± 30 lb ft)

• D5K Track-Type Tractor with SystemOne track – 300 ± 50 N·m (220 ± 35 lb ft)

• Tighten all of the track bolts for an additional 120 degrees

Ripper Linkage and Cylinder Bearings - Lubricate

• Lubricate the two fittings (1) for the upper link pin on each side of the ripper.

• Lubricate two fittings (2) at the top of the cylinder. Lubricate two fittings (3) at the bottom of the cylinder.

• Lubricate two fitting (4) on each side for the lower link.

Check

• Check the track adjustment. Check for wear and for excessive dirt buildup.

• If tracks are too tight wear of the components will accelerate. If tracks are too loose wear of the components will accelerate.

• Move the machine forward for a distance of two times the length of the machine. Allow the machine to stop without the use of the service brake. Shut off the engine.

• Stand on the track between the front idler and the track carrier roller in order to produce as much track sag as possible.

• Measure the track sag in two places on each track. a. Place a tight string or a straight edge on top of the grousers between the carrier roller and front idler. Measure the distance from the straight edge to the grouser tip at the lowest point of sag. b. Place a tight string or a straight edge on top of the grousers between the carrier roller and sprocket. Measure the distance from the straight edge to the grouser tip at the lowest point of sag.

• Total the two measurements. Refer to Table 14 in order to determine the correct sag.

• If this dimension is not correct, adjust the track.

Loosen the relief valve only one turn.

• Move the machine forward for a distance of two times the length of the machine. Allow the machine to a stop without the use of the service brakes. Shut off the engine. Adjust the tracks while you are in the machine's typical operating conditions. If packing conditions prevail on the job, the tracks should be adjusted with packing material.

• Note: Perform Steps 2 through 4 on both sides of the machine

• Remove the cover for the track adjusting mechanism.

• By using a manual grease gun, add multipurpose grease (MPGM) through track adjustment valve (4) in order to tighten the track. To loosen the track, rotate relief valve (5) counterclockwise. Then, open the track adjustment valve by one full turn and allow the grease to escape. Then close relief valve (5).

• Close the valve cover.

• Repeat the procedure for the other track.

Use the recommendations in order to extend the life of the undercarriage. Use the recommendations in order to avoid excessive downtime.

• During the machine operation, listen for unusual squeaking and for unusual squealing. This can indicate a dry joint.

• Check the machine for dry joints weekly. Check for dry joints immediately after machine operation. After machine operation, lightly touch the end of each track pin or bushing. Touch the track pin or the track bushing with the back of your hand. Make a mark on any dry track pin joint that is very hot to the touch.