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How To: 2,000-Hour Planned Maintenance on a Cat® Dozer
Estimated read time: 5 minutes
Every time your Cat® equipment reaches 2,000 service hours, it's time for PM4 maintenance. While the exact service requirements can vary by machine, here's what you can expect for a Cat D6 XE Dozer. Always refer to your Operation and Maintenance Manual (OMM) for safety procedures, and don't forget to wear appropriate personal protective equipment (PPE).
Check out this video to see how to perform this maintenance before you dive in:
Do your maintenance in a clean environment and on a level surface. Let your equipment coast to a stop because this will help when you check track tension. Engage the park brake, lower implements to the ground and lock out the hydraulics.
You can order all the necessary parts for your planned maintenance at Parts.Cat.com. Enter your machine’s serial number to find the specific parts and Cat Self-Service Options (SSO) tailored for your equipment. SSOs provide detailed service instructions along with recommended parts and tools.
Before starting the service, take a walk around your machine to inspect for leaks, rust or any other signs of damage.
Take Fluid Samples
To begin this routine Cat D6 XE Dozer maintenance, you'll need to collect S•O•SSM Services samples. Start the engine so you can take coolant, engine, hydraulic and transmission samples. They all need to be taken while the engine is running and the compartments are at operating temperature. Always drain a bit of fluid before you start filling the bottle so that you’re getting an accurate analysis of fluid health.
- Coolant: Insert the tube into the coolant S•O•S port and pump out the coolant sample.
- Oil samples: Take samples for the engine, hydraulics and transmission. The transmission and engine aren’t pressurized, so you have to pump those samples out.
Once these samples are collected, you can turn off the engine and use a pump to take separate fluid samples from both final drives.
Inspect the Electrical System
Before this inspection, shut off the D6 XE’s electrical system for your safety. Check enclosures, cables, harnesses and ground straps throughout the machine. Replace any missing hardware, clean off built-up debris and make any necessary repairs.
Also, wipe down the batteries and check for leaks or damage. Ensure the terminals are secure.
Drain Engine, Powertrain Oils
For PM4 maintenance, you’ll drain and replace the engine and powertrain oils.
- Engine oil: Open the cover under the machine, remove the plate in the belly pan and drain the engine oil. This will take a while, so it’s recommended to do this early on in your service.
- Powertrain oil: At the back of the machine, remove the powertrain oil plug. Use the OMM-recommended tooling — such as a swivel and a hose — to drain the oil into a suitable container. Replace the oil filter, and then clean the plug and check its o-ring for damage before reinstalling it.
Cleaning Screens and Replacing Fuel Filters
Under the machine, disconnect the hose, and remove the suction screen and the generator scavenge screen. Clean them in solvent and reinstall them. Clean any buildup on the generator plug and then reinstall it.
Now, shut off the fuel valve at the back of the machine and drain any sediment. Replace the primary and secondary fuel filters, being sure to coat the new seals with clean diesel. Never prefill your fuel filters. Follow the instructions in your OMM to prime the fuel system.
Undercarriage Maintenance
- Track and frame: Check the equalizer bar end pins, front roller frame seals and track shoes for any signs of wear or damage. Adjust the track tension as needed after you have checked tension using a string and measuring tape.
- Final drive oil: Move the machine so the oil level mark is horizontal and the drain plug is facing downward. Drain the oil, inspect the magnetic plug and refill with new oil. Repeat this process on the other side.
- Pivot shaft oil: Check the oil level on both sides of the track and add oil if it's low
Remaining Filter Maintenance
Replace the engine oil filter, ensuring the new filter’s seal is coated with fresh engine oil.
If you are using Cat HYDO Advanced and do S•O•S analysis at the recommended intervals, you might be able to extend the drain interval to 6,000 hours. Otherwise, drain your hydraulic oil every 2,000 hours. Replace the filter as well.
Replace the fresh cabin air filter outside the cab. Inspect the recirculating filter in the cab, and replace it if it’s dirty.
While in this area, remove and clean the fuel tank strainer, and replace the fuel cap filter.
Final Tasks & Checks
- Serpentine belt: Inspect the serpentine belt and replace it if it's damaged.
- Breather: Replace the breather by removing the outlet hose and loosening the clamp.
- ROPS/FOPS: Check the bolts, making sure they are secure and not damaged. If you find any damage to your rollover or falling object protective structure, get it serviced immediately.
- Winch maintenance: If equipped, replace the winch oil and lubricate the roller and fairlead assembly.
Don’t forget to shut all compartments and put guards and steps back in operating position. Also turn the electrical system back on.
With thorough planned maintenance, you can help keep your Cat equipment in top working condition, ready for its next 2,000 hours on the job.
Haven't reached 2,000 hours yet? We have guides for 250-hour, 500-hour and 1,000-hour maintenance, too.
For more information and support, contact your Cat dealer. And always check your Operation and Maintenance Manual for specific instruction and safety procedures.
