Caterpillar D3K, D4K and D5K: Maintenance (Every 500 Service Hours or 3 Months)

If you select an interval for oil and filter change that is too long, you may damage the engine.

• Open the left engine access door.

• Remove the lower service access door on the left side of the machine. A. Obtain the regularly scheduled oil sample, if necessary.

• Remove the crankcase drain access cover, which is in the crankcase guard.

• Open crankcase drain valve (4). Allow the oil to drain into a suitable container.

• Remove engine oil filter element (3) and discard the engine oil filter element properly. Make sure that all of the old filter seal is removed from the filter base.

• Apply a thin coat of clean engine oil to the seal on the new filter. Install new engine oil filter element (3) by hand.

• Instructions for the installation of the filters are printed on the side of each Caterpillar spin-on filter. For non-Caterpillar filters, refer to the installation instructions that are provided by the supplier of the filter.

• Close crankcase drain valve (4). Replace the crankcase drain access cover that is in the crankcase guard.

• Remove the oil filler cap (1). Fill the crankcase with new oil. See Operation and Maintenance Manual, “ Capacities (Refill)”. Clean the oil filler cap and install the oil filler cap.

• Always measure the oil level with dipstick (2) in order to ensure that the correct amount of oil was added.

• On the dipstick, maintain the oil level between the “ADD” mark and the “FULL” mark.

• Replace the lower service access door on the left side of the machine.

• Close the left engine access door.

Fuel System Secondary Filter - Replace

• The secondary fuel filter is located on the front of the engine on the left side. Open the left engine access door.

• Place a suitable container under the fuel filter in order to catch any fuel that might spill. Clean up any spilled fuel.

• Clean the outside of secondary fuel filter (1). Use a suitable tool in order to remove the fuel filter from the engine and dispose of the filter in a safe place.

• If maintenance is required, remove the filter.

• Clean filter mounting base. Make sure that the old seal is removed.

• Ensure that dirt can not enter the new fuel filter. Do not fill the filter with fuel before the fuel filter is installed.

• Apply a thin coat of clean diesel fuel to the seal on the new filter. Install a new fuel filter by hand.

• Note: Instructions for the installation of the filters are printed on the side of each Caterpillar spin-on filter. For non-Caterpillar filters, refer to the installation instructions that are provided by the supplier of the filter.

• Prime the fuel system. Refer to the Operation and Maintenance Manual, “Fuel System - Prime” for more information.

• Before you start the engine, make sure that the drain valves are completely closed. Start the engine. Check for leaks.

• Close the left engine access door.

Note: Do not fill fuel filters before installation in any circumstance. Do not open high pressure fuel lines in order to bleed air from the fuel system.

• Open the access cover on the left side of the machine.

• Place a suitable container under the water separator in order to catch any fuel that might spill. Clean up any spilled fuel. Clean the outside of the water separator.

• Install a suitable tube onto drain (1). Open the drain (1). Allow the fluid to drain into a suitable container

• Tighten the drain (1) by hand.

• If equipped, remove the wiring harness from the sensor on the bottom of the glass bowl by depressing the clip on the wire connector.

• Rotate bowl (3) counterclockwise in order to remove the bowl. Remove O ring seal (2). Clean the bowl.

• Use 1U-8760 Chain Wrench in order to remove old canister (4).

• Lubricate O ring seal (5 ) with clean engine oil on the new canister. Install new canister (6). Spin on the canister until the O ring seal contacts the sealing surface. Then rotate the canister 360 degree in order to tighten the canister correctly.

• Remove cap (8) from the threaded end of the new canister and remove new O ring seal (7). Install the new O ring seal into bowl (3).

• Lubricate O ring seal (7) with clean engine oil. Install the bowl onto the new canister. Tighten the bowl to 15 N·m (11 lb ft).

• If equipped, install the wiring harness to the sensor. Open the fuel supply valve.

• Remove the container and dispose of the fluid in a safe place.

• The secondary filter must be replaced at the same time as the water separator element. Refer to the Operation and Maintenance Manual , “Fuel System Secondary Filter - Replace”.

• Note: Do not start the engine until all service to the fuel system is complete. For instructions about priming the fuel system, refer to Operation and Maintenance Manual, “Fuel System - Prime”.

• Close the access cover on the left side of the machine.

Illustration 160

Illustration 161

Illustration 162