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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
05/03/2021

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

53 steps
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.
  • Backup Alarm - Test

  • Backup Alarm - Test

    Screenshot2021-02-04at11.39.55AM.png
  • 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.

  • Screenshot2021-02-04at11.39.46AM.png
  • 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.

  • Battery - Recycle

  • Always recycle a battery. Never discard a battery.

  • Always return used batteries to one of the following locations:

  • 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.

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  • Screenshot2021-02-04at12.06.15PM.png
  • Screenshot2021-02-04at12.06.43PM.png
  • Belt - Inspect/Replace

  • Inspect

  • 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:

  • 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)

  • Test:

  • Bulldozer Power Angling Tilt Hinge Pins - Lubricate

    Screenshot2021-02-04at1.36.11PM.png
  • 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.

    Screenshot2021-02-04at1.41.28PM.png
  • Cab Filter (Recirculation) - Clean/Inspect/Replace

    Screenshot2021-02-04at1.44.42PM.png
  • Circuit Breakers - Reset

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

  • Screenshot2021-02-04at1.47.03PM.png
  • Screenshot2021-02-04at1.48.00PM.png
  • Repair the fins if found defective.

    Screenshot2021-02-04at1.49.29PM.png
  • If the coolant in the machine is changed to Extended Life Coolant from another type of coolant, see Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations”.

    Screenshot2021-02-04at1.53.27PM.png
  • Cutting Edges and End Bits - Inspect/Replace

  • 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:

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  • Screenshot2021-02-04at2.41.22PM.png
  • Screenshot2021-02-04at2.41.22PM.png
  • 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.

  • 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:

    Screenshot2021-02-04at3.06.02PM.png
  • Illustration 138

  • Engine Air Precleaner - Clean

  • Screenshot2021-02-04at3.08.54PM.png
  • Screenshot2021-02-04at3.09.41PM.png
  • 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.

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

  • Ether Starting Aid Cylinder - Replace

    Screenshot2021-02-04at3.13.50PM.png
  • 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.

  • 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.

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  • Oil Filter - Inspect

  • Inspect A Used Filter for Debris

  • Screenshot2021-02-04at3.38.09PM.png
  • 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.

  • Screenshot2021-02-04at3.40.07PM.png
  • Screenshot2021-02-04at3.40.31PM.png
  • 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

  • Radiator Pressure Cap - Clean/Replace

  • 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

    Screenshot2021-02-04at3.55.23PM.png
  • Windows - Clean

  • Illustration 219

    Screenshot2021-02-04at3.56.53PM.png

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