D5R2 and D6R2 Track-Type Tractors Visual Inspection Caterpillar

Visual Inspection

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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Do not check for leaks with your hands. Pin hole (very small) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate pin hole leaks.

Implement System

When you are troubleshooting a problem, a visual inspection of the system is the first step. Turn the engine OFF before you inspect the machine. Lower the attachments to the ground. Place all controls in the PARK or HOLD position. After performing the visual inspection, check the operation of the machine and note any unusual noises.

Check the Fluid Levels

1. Fill all of the oil reservoirs to the correct level.
   

   ReferenceFor D5R2 models, refer to the latest revision of the Operation and Maintenance Manual, SEBU9258

   ReferenceFor D6R2 models, refer to the latest revision of the Operation and Maintenance Manual, SEBU9246
   

   Expected Results

   • The oil levels are at the correct level.

   Results

   • OKAY: Proceed to "Check for Oil Leaks".

Check for Oil Leaks

1. Inspect these components for leaks and for damage: oil lines, hoses and fittings.

2. Look under the machine for oil that has leaked from the machine onto the ground.

   Expected Results

   • No leaks exist.

   Results

   • OKAY: Proceed to "Check the Electrical System".

   • NOT OKAY: Repair all leaks. Check the machine for the original problem. If the conditions are not resolved, proceed to "Check the Electrical System".

Check the Electrical System

1. Inspect the wires and check the electrical connectors to the component that is suspect.

   Expected Results

   • The wires and the electrical connectors are not damaged. The electrical connectors are clean.

   Results

   • OKAY: Proceed to "Check for Oil Contamination".

   • NOT OKAY: Replace any damaged wires. Replace any damaged electrical connectors. Ensure that all of the seals are properly in place. Check the machine for the original problem. If the conditions are not resolved, proceed to "Check for Oil Contamination".

Check for Oil Contamination

1. Use the 175-7546 Oil Filter Cutter Gp to cut open spin-on filters to inspect the filter media for contaminants.

2. Check the oil for air and for excessive particles. Air in the oil causes the oil to foam. If particles are in the oil, the oil appears sandy.

3. Check the hydraulic oil by taking an oil sample from the S·O·S Sampling Valve next to the steering charge filter.
   

   ReferenceFor D5R2 models refer to the latest revision of the Operation and Maintenance Manual, SEBU9258, "Hydraulic System Oil Sample - Obtain".

   ReferenceFor D6R2 models refer to the latest revision of the Operation and Maintenance Manual, SEBU9246, "Hydraulic System Oil Sample - Obtain".

Check for Particles in the Oil

1. Shiny steel particles indicate a pump failure.

2. Rubber particles indicate a seal failure or hose failure.

3. If metal particles or rubber particles are found, then all components of the implement, steering, and fan systems must be washed.

4. Replace all damaged parts with new parts.
   

   ReferenceFor D5R2 models refer to the latest revision of the Disassembly and Assembly, UENR4120 manual

   ReferenceFor D6R2 models refer to the latest revision of the Disassembly and Assembly, UENR4110 manual

   Expected Results

   • The original problem is resolved.

   Results

   • OKAY: Stop.

   • NOT OKAY: The cause of the problem is uncertain. Call technical support with the information that has been gathered.

Power Train System

When you are troubleshooting a problem, a visual inspection of the system is the first step. Turn the engine OFF before you inspect the machine. Lower the attachments to the ground. Place all controls in the PARK or HOLD position. After performing the visual inspection, check the operation of the machine and note any unusual noises.

Check the Fluid Levels

1. Fill the oil reservoirs to the correct level.
   

   ReferenceFor D5R2 models, refer to the latest revision of the Operation and Maintenance Manual, SEBU9258

   ReferenceFor D6R2 models, refer to the latest revision of the Operation and Maintenance Manual, SEBU9246

   Expected Results

   • The oil levels are at the correct level.

   Results

   • OKAY: Proceed to "Check the Level of the Final Drive Oil".

   • NOT OKAY: Add oil if the oil level is low. Drain oil if the oil level is high. Maintain the correct oil levels. Check the machine for the original problem. If the conditions are not resolved, proceed to "Check the Level of the Final Drive Oil".

Check the Level of the Final Drive Oil

1. Position one final drive so that the oil level mark is horizontal.

2. Remove the check/fill plug at the final drive.

3. Use the final drive oil level mark to check the level of the final drive oil.

4. Repeat the procedure to check the final drive oil level for the other side of the machine.
   

   ReferenceFor D5R2 models refer to the latest revision of the Operation and Maintenance Manual, SEBU9258, "Final Drive Oil Level - Check".

   ReferenceFor D6R2 models refer to the latest revision of the Operation and Maintenance Manual, SEBU9246, "Final Drive Oil Level - Check".
   

   Expected Results

   • The oil level is at the bottom of the filler plug opening.

   Results

   • OKAY: Proceed to "Check for Oil Leaks".

   • NOT OKAY: Add oil if the level of the oil is low. Drain oil if the level of the oil is high. Inspect the seal that is used for the check/fill plug. Replace the seal if the seal is damaged. Clean the plug and install the check/fill plug. Check the machine for the original problem. If the conditions are not resolved, proceed to "Check for Oil Leaks".

Check for Oil Leaks

1. Inspect these components for leaks and for damage: oil lines, hoses and fittings.

2. Look under the machine for oil that has leaked from the machine onto the ground.

   Expected Results

   • No leaks exist.

   Results

   • OKAY: Proceed to "Check the Electrical System".

   • NOT OKAY: Repair all leaks. Check the machine for the original problem. If the conditions are not resolved, proceed to "Check the Electrical System".

Check the Electrical System

1. Inspect the wires and check the electrical connectors to the power train components and to the brake control valves (if equipped).

   Expected Results

   • The wires and the electrical connectors are not damaged. The electrical connectors are clean.

   Results

   • OKAY: Proceed to "Check the Track".

   • NOT OKAY: Replace any damaged wires. Replace any damaged electrical connectors. Ensure that all of the seals are properly in place. Check the machine for the original problem. If the conditions are not resolved, proceed to "Check the Track".

Check the Track

1. Check the track for wear and for excessive dirt buildup.

2. Visually check the adjustment of the track.
   

   ReferenceFor D5R2 models refer to the latest revision of the Operation and Maintenance Manual, SEBU9258, "Track - Adjust".

   ReferenceFor D6R2 models refer to the latest revision of the Operation and Maintenance Manual, SEBU9246, "Track - Adjust".
   

3. Check the torque of the track shoe bolts.
   

   ReferenceFor D5R2 models refer to the latest revision of the Specifications, System Operation, Testing and Adjusting, UENR4119, "Tracks".

   ReferenceFor D6R2 models refer to the latest revision of the Specifications, System Operation, Testing and Adjusting, UENR4109, "Tracks".
   

   Expected Results

   • The bolt torque for the track shoes is correct.

   • The track is adjusted correctly.

   Results

   • OKAY: Proceed to "Check for Oil Contamination".

   • NOT OKAY: Repair components and/or replace components, if necessary. Use the references that are listed for the correct procedures and for the specifications. Check the machine for the original problem. If the conditions are not resolved, proceed to "Adjust the Track".

Adjust the Track

ReferenceFor D5R2 models refer to the latest revision of the Operation and Maintenance Manual, SEBU9258, "Track - Adjust".

ReferenceFor D6R2 models refer to the latest revision of the Operation and Maintenance Manual, SEBU9246, "Track - Adjust".

Expected Results

• The track is adjusted correctly.

• The torque for the track shoes is correct.

Results

• CONTINUE: Proceed to "Check for Oil Contamination".

Check for Oil Contamination

1. Check the oil for air and for excessive particles. Air in the oil causes the oil to foam. If particles are in the oil, the oil appears sandy.

2. Check the power train oil system for contamination by examining the oil on the dipstick or by taking an oil sample from the S·O·S Sampling Valve.

3. Check the torque converter scavenge screen (if equipped) for foreign particles.

4. Check the element of the power train oil filter for foreign particles.
   

   ReferenceFor D5R2 models refer to the latest revision of the Specifications, System Operation, Testing and Adjusting, UENR4119 for the correct procedure for sampling the power train oil.

   ReferenceFor D6R2 models refer to the latest revision of the Specifications, System Operation, Testing and Adjusting, UENR4109 for the correct procedure for sampling the power train oil.

   Expected Results

   • An excessive amount of air is not present in the oil. Excessive amounts of particles are not present in the oil.

   Results

   • OKAY: Continue troubleshooting if the original problem exists.

   • AIR IS PRESENT IN THE OIL: Proceed to "Check for Air in the Oil".

   • PARTICLES ARE PRESENT IN THE OIL: Proceed to "Check for Particles in the Oil".

Check for Air in the Oil

ReferenceRefer to Troubleshooting, "Power Train Oil" in this module.

Check for Particles in the Oil

1. Crystal particles and/or particles of grit indicate a failure of a clutch.

2. Shiny steel particles indicate a pump failure.

3. Rubber particles indicate a seal failure or hose failure.

4. Aluminum particles indicate a torque converter failure.

5. If excessive metal particles or rubber particles are found, then all components of the power train must be washed. The presence of some metal or rubber particles are considered normal during the break-in period.

6. Replace all damaged parts with new parts.
   

   ReferenceFor D5R2 models refer to the latest revision of the Disassembly and Assembly, UENR4120 manual.

   ReferenceFor D6R2 models refer to the latest revision of the Disassembly and Assembly, UENR4110 manual.

   Expected Results

   • The original problem is resolved.

   Results

   • OKAY: Stop.

   • NOT OKAY: The cause of the problem is uncertain. Call technical support with the information that has been gathered.