SEBU8213-04

October 2009

Operation and
Maintenance
Manual
D3K, D4K and D5K Track-Type
Tractors
JTD1-Up (Machine)
FFF1-Up (Machine)
JLF1-Up (Machine)
LLL1-Up (Machine)
MMM1-Up (Machine)
RRR1-Up (Machine)
WWW1-Up (Machine)
YYY1-Up (Machine)

SAFETY.CAT.COM

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 SEBU8213-04
i03653330
Maintenance Interval Schedule
SMCS Code: 7000
Ensure that all safety information, warnings and
instructions are read and understood before any
operation or any maintenance procedures are
performed.
The user is responsible for the performance of
maintenance, including all adjustments, the use of
proper lubricants, Àuids, ¿lters, and the replacement
of components due to normal wear and aging. Failure
to adhere to proper maintenance intervals and
procedures may result in diminished performance of
the product and/or accelerated wear of components.
Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST,
in order to determine the maintenance intervals.
Products that operate in severe operating conditions
may require more frequent maintenance.
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be
performed.
Note: If Cat HYDO Advanced 10 hydraulic oil is
used, the hydraulic oil change interval will change.
The normal interval of 2000 hours is extended to
3000 hours. S·O·S services may extend the oil
change even longer. Consult your Caterpillar dealer
for details.
When Required
Battery - Recycle .................................................. 91
Battery or Battery Cable - Inspect/Replace .......... 92
Circuit Breakers - Reset ........................................ 96
Condenser (Refrigerant) - Clean .......................... 97
Cutting Edges and End Bits - Inspect/Replace ... 103
Engine Air Filter Primary Element - Clean/
Replace ............................................................. 103
Engine Air Filter Secondary Element - Replace .. 105
Engine Air Precleaner - Clean ............................ 106
Ether Starting Aid Cylinder - Replace ................. 109
Free Spool Drag - Adjust ..................................... 111
Fuel System - Prime ............................................ 113
Fuel System Water Separator - Drain .................. 115
Fuel Tank Cap - Clean ......................................... 118
Fuses - Replace ................................................... 119
Oil Filter - Inspect ................................................ 126
Radiator Core - Clean ......................................... 126
Radiator Pressure Cap - Clean/Replace ............ 127
Ripper - Inspect/Replace .................................... 128
Winch Cable - Replace ....................................... 133
Window Washer Reservoir - Fill .......................... 135
Window Wipers - Inspect/Replace ...................... 136
Windows - Clean ................................................. 136
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89
Maintenance Section
Maintenance Interval Schedule
Every 10 Service Hours or Daily
Backup Alarm - Test .............................................. 91
Brakes, Indicators and Gauges - Test ................... 94
Bulldozer Power Angling Tilt Hinge Pins -
Lubricate ............................................................. 95
Cab Filter (Fresh Air) - Clean/Inspect/Replace ..... 96
Cooling System Coolant Level - Check .............. 100
Engine Oil Level - Check .................................... 107
Hydraulic System Oil Level - Check ................... 124
Seat Belt - Inspect .............................................. 129
Winch Cable - Inspect ......................................... 132
Winch Fairlead Rollers - Lubricate ...................... 135
Every 50 Service Hours or Weekly
Cab Filter (Recirculation) - Clean/Inspect/
Replace ............................................................... 96
Front Idler Position - Check/Adjust ...................... 111
Ripper Linkage and Cylinder Bearings -
Lubricate ........................................................... 127
Track - Check/Adjust ........................................... 130
Track Pins - Inspect ............................................ 131
Every 250 Service Hours or Monthly
Belt - Inspect/Replace ........................................... 93
Engine Oil Sample - Obtain ................................ 108
Final Drive Oil Level - Check ............................... 110
Fuel Tank Water and Sediment - Drain ................ 118
Track Roller Frame - Inspect .............................. 132
Winch Oil Level - Check ..................................... 134
Initial 500 Hours (for New Systems, Re¿lled
Systems, and Converted Systems)
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 101
Every 500 Service Hours
Cooling System Coolant Sample (Level 1) -
Obtain ............................................................... 100
Engine Air Precleaner - Clean ............................ 106
Final Drive Oil Sample - Obtain ........................... 111
Hydraulic System Oil Sample - Obtain ............... 125
Winch Oil Sample - Obtain ................................. 134
Every 500 Service Hours or 3 Months
Engine Oil and Filter - Change ........................... 108
Fuel System Secondary Filter - Replace ............. 114
Fuel System Water Separator - Replace ............. 116
Every 500 Service Hours or 1 Year
Trunnion - Adjust ................................................. 132
Winch Drum Bearing - Lubricate ......................... 135
Every 1000 Service Hours or 6 Months
Battery - Inspect .................................................... 91
Engine Valve Lash - Check ................................. 109
 90 SEBU8213-04
Maintenance Section
Maintenance Interval Schedule

Hydraulic System Oil Filter - Replace ................. 123

Rollover Protective Structure (ROPS) - Inspect .. 129
Winch Oil Filter - Replace ................................... 133

Every 2000 Service Hours or 1 Year

Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 101
Final Drive Oil - Change ...................................... 110
Hydraulic System Oil - Change ........................... 120
Winch Oil - Change ............................................. 133
Winch Vent Plug - Clean ..................................... 134

Every 3000 Service Hours or 2 Years

Cooling System Water Temperature Regulator -
Clean/Replace .................................................. 102
Engine Air Filter Primary Element - Clean/
Replace ............................................................. 103
Engine Air Filter Secondary Element - Replace .. 105

Every 3 Years After Date of Installation or

Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 129

Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .... 99

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 97

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