320C Cat PDF

MAINTENANCE INTERVALS
Operation and Maintenance

Manual Excerpt

2010 Caterpillar
All Rights Reserved
SEBU7342-08
May 2008
Operation and
Maintenance
Manual
320C Excavator
ANB1-Up (Machine)
MAB1-Up (Machine)
PAB1-Up (Machine)
AMC1-Up (Machine)
BDC1-Up (Machine)
CCD1-Up (Machine)
SBN1-Up (Machine)
BER1-Up (Machine)
RAW1-Up (Machine)
SAFETY.CAT.COM
152 SEBU7342-08
Maintenance Section
Maintenance Interval Schedule
i03023880 Window Wiper - Inspect/Replace ........................ 213

Windows - Clean ................................................. 214
Every 10 Service Hours or Daily for First 100
SMCS Code: 7000
Hours
Ensure that all safety information, warnings and Boom Cylinder Head (Long Reach Configuration) -
instructions are read and understood before any Lubricate ........................................................... 157
operation or any maintenance procedures are Boom and Stick Linkage - Lubricate ................... 157
performed. Boom, Stick and Bucket Linkage (Long Reach
Configuration) - Lubricate ................................. 158
The user is responsible for the performance of Bucket Linkage - Lubricate ................................. 160
maintenance, including all adjustments, the use of
proper lubricants, fluids, filters, and the replacement Every 10 Service Hours or Daily
of components due to normal wear and aging. Failure
to adhere to proper maintenance intervals and Cooling System Coolant Level - Check .............. 170
procedures may result in diminished performance of Engine Oil Level - Check .................................... 174
the product and/or accelerated wear of components. Fuel System Water Separator - Drain ................. 181
Fuel Tank Water and Sediment - Drain ............... 183
Use mileage, fuel consumption, service hours, or Hydraulic System Oil Level - Check ................... 198
calendar time, WHICH EVER OCCURS FIRST, Indicators and Gauges - Test .............................. 201
in order to determine the maintenance intervals. Seat Belt - Inspect .............................................. 205
Products that operate in severe operating conditions Track Adjustment - Inspect ................................. 212
may require more frequent maintenance. Travel Alarm - Test .............................................. 212
Undercarriage - Check ........................................ 213
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be Every 10 Service Hours or Daily for Machines
performed. Used in Severe Applications
Note: If Cat HYDO Advanced 10 hydraulic oil is Boom, Stick and Bucket Linkage (Long Reach
used, the hydraulic oil change interval will change. Configuration) - Lubricate ................................. 158
The normal interval may be extended to 3000 hours Bucket Linkage - Lubricate ................................. 160
for machine hydraulic systems over second and third
choice oils when you follow the maintenance interval Every 50 Service Hours or Weekly
schedule for oil filter changes and for oil sampling that
is stated in the Operation and Maintenance Manual Boom, Stick and Bucket Linkage (Long Reach
. SOS services may extend the oil change even Configuration) - Lubricate ................................. 158
longer. Consult your Caterpillar dealer for details.
Every 100 Service Hours or 2 Weeks
When Required Bucket Linkage - Lubricate ................................. 160
Air Conditioner/Cab Heater Filter (Recirculation) -
Inspect/Replace ................................................ 154 Every 100 Service Hours or 2 Weeks for
Battery - Recycle ................................................ 154 Machines Used in Severe Applications
Battery or Battery Cable - Inspect/Replace ........ 155
Bucket Linkage - Inspect/Adjust ......................... 159 Boom Cylinder Head (Long Reach Configuration) -
Bucket Tips - Inspect/Replace ............................ 161 Lubricate ........................................................... 157
Cab Air Filter (Fresh Air) - Clean/Replace .......... 164 Boom and Stick Linkage - Lubricate ................... 157
Circuit Breakers - Reset ...................................... 164 Bucket Linkage - Lubricate ................................. 160
Engine Air Filter Primary Element - Clean/ Hydraulic System Oil Filter (Case Drain) -
Replace ............................................................. 171 Replace ............................................................. 190
Engine Air Filter Secondary Element - Replace .. 173 Hydraulic System Oil Filter (Pilot) - Replace ....... 193
Fuel Inlet Screen - Clean .................................... 179
Fuel System - Prime ........................................... 181 Initial 250 Service Hours
Fuses - Replace .................................................. 184
Engine Valve Lash - Check ................................. 178
Hydraulic Tank Screen - Clean ........................... 200 Final Drive Oil - Change ..................................... 178
Oil Filter - Inspect ................................................ 202
Hydraulic System Oil Filter (Case Drain) -
Radiator Core - Clean ......................................... 202
Replace ............................................................. 190
Radiator, Aftercooler and Oil Cooler Cores - Hydraulic System Oil Filter (Pilot) - Replace ....... 193
Clean ................................................................. 204
Hydraulic System Oil Filter (Return) - Replace ... 194
Track Adjustment - Adjust ................................... 210
Swing Drive Oil - Change ................................... 206
Window Washer Reservoir - Fill .......................... 213
SEBU7342-08 153
Maintenance Section
Every 250 Service Hours Boom and Stick Linkage - Lubricate ................... 157
Engine Valve Lash - Check ................................. 178
Cooling System Coolant Sample (Level 1) - Final Drive Oil Level - Check .............................. 179
Obtain ............................................................... 168 Hydraulic System Oil Filter (Case Drain) -
Engine Oil Sample - Obtain ................................ 176 Replace ............................................................. 190
Final Drive Oil Sample - Obtain .......................... 179 Hydraulic System Oil Filter (Pilot) - Replace ....... 193
Every 250 Service Hours or Monthly Swing Drive Oil - Change ................................... 206
Belts - Inspect/Adjust/Replace ............................ 155
Condenser (Refrigerant) - Clean ........................ 165 Every 1000 Service Hours of Partial Hammer
Swing Bearing - Lubricate ................................... 206 Use (50% of Service Hours)
Swing Drive Oil Level - Check ............................ 208 Hydraulic System Oil - Change ........................... 186
Every 250 Service Hours of Partial Hammer Every 2000 Service Hours or 1 Year
Use (50% of Service Hours)
Final Drive Oil - Change ..................................... 178
Hydraulic System Oil Filter (Case Drain) - Hydraulic System Oil - Change ........................... 186
Replace ............................................................. 190 Receiver Dryer (Refrigerant) - Replace .............. 205
Hydraulic System Oil Filter (Pilot) - Replace ....... 193 Swing Gear - Lubricate ....................................... 209
Every 250 Service Hours of Continuous Every Year

Hammer Use
Cooling System Coolant Sample (Level 2) -
Hydraulic System Oil Filter (Return) - Replace ... 194 Obtain ............................................................... 169
Initial 500 Hours (for New Systems, Refilled Every 3 Years After Date of Installation or
Systems, and Converted Systems) Every 5 Years After Date of Manufacture
Cooling System Coolant Sample (Level 2) - Seat Belt - Replace ............................................. 206
Obtain ............................................................... 169
Every 6000 Service Hours or 3 Years
Every 500 Service Hours
Cooling System Coolant Extender (ELC) - Add .. 167
Hydraulic System Oil Sample - Obtain ............... 199
Swing Drive Oil Sample - Obtain ........................ 208 Every 12 000 Service Hours or 6 Years
Every 500 Service Hours or 3 Months Cooling System Coolant (ELC) - Change ........... 165
Engine Crankcase Breather - Clean ................... 174

Engine Oil and Filter - Change ........................... 176
Fuel System Filter - Replace .............................. 180
Fuel System - Prime ........................................... 181
Fuel System Primary Filter (Water Separator)
Element - Replace ............................................ 182
Fuel Tank Cap and Strainer - Clean ................... 183
Every 500 Service Hours of Partial Hammer

Use (50% of Service Hours)
Every 600 Service Hours of Continuous

Hammer Use
Hydraulic System Oil - Change ........................... 186
Every 1000 Service Hours or 6 Months

Battery - Clean .................................................... 154
Battery Hold-Down - Tighten ............................... 154
Boom Cylinder Head (Long Reach Configuration) -
Lubricate ........................................................... 157
154 SEBU7342-08
Maintenance Section
Air Conditioner/Cab Heater Filter (Recirculation) - Inspect/Replace
i01520787 4. After you clean the filter element, inspect the filter
element. If the filter element is damaged or badly
Air Conditioner/Cab Heater contaminated, use a new filter element. Make sure
Filter (Recirculation) - that the filter element is dry.
Inspect/Replace
i00934864
SMCS Code: 1054-040-A/C; 1054-510-A/C
Battery - Clean
NOTICE SMCS Code: 1401-070
An air recirculation filter element plugged with dust will
result in decreased performance and service life to the Clean the battery surface with a clean cloth. Keep the
air conditioner or cab heater. terminals clean and keep the terminals coated with
petroleum jelly. Install the post cover after you coat
To prevent decreased performance, clean the filter el- the terminal post with petroleum jelly.
ement, as required.
i00993589
Battery - Recycle
SMCS Code: 1401-561
Always recycle a battery. Never discard a battery.
Always return used batteries to one of the following

locations:
A battery supplier
An authorized battery collection facility
Recycling facility
i00934872
Battery Hold-Down - Tighten

SMCS Code: 7257
Tighten the hold-downs for the battery in order to

prevent the batteries from moving during machine
operation.
g00685718
Illustration 287
The recirculation filter is on the lower left side of the

cab.
1. To remove the filter element, slide the element

straight up.
2. Refer to Operation and Maintenance Manual,

General Hazard Information before using
pressure air to clean the air filter element.
3. Clean the filter element with a maximum of

200 kPa (30 psi) pressure air.
SEBU7342-08 155
Maintenance Section
Battery or Battery Cable - Inspect/Replace
i01913589 i03026885
Battery or Battery Cable - Belts - Inspect/Adjust/Replace

Inspect/Replace SMCS Code: 1356; 1357-025; 1357-040;
1357-510; 1357; 1358-025; 1358-510; 1359-025;
SMCS Code: 1401-040; 1401-510; 1401-561; 1401;
1359-025-BE; 1359-040-BE; 1359-040;
1402-040; 1402-510 1359-510-BE; 1359-510; 1361-025-BE; 1361-025;
1361-040-BE; 1361-040; 1361-510; 1361-510-BE;
1397-025; 1397-040; 1397-510; 1405-025;
1405-025-BE; 1405-036; 1405-040-BE; 1405-040;
Personal injury can result from battery fumes or 1405-510-BE; 1405-510; 1802-025; 1802-510
explosion.
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.
g00688114
Illustration 288
1. Turn the engine start switch key to the OFF The belt assembly for the tier I engines is for the following serial
position. Turn all of the switches to the OFF numbers: (S/N: ANB1-UP; BCB1-UP; BDB1-UP; AMC1-UP;
position. BDC1-UP; CCD1-UP; ALF1-UP; AKH1-UP; BER1-UP)
2. Turn the battery disconnect switch to the OFF

position. Remove the key.
3. Disconnect the negative battery cable at the

battery.
4. Disconnect the positive battery cable at the

battery.
5. Disconnect the battery cables at the battery

disconnect switch. The battery disconnect switch
is connected to the machine frame.
6. Make necessary repairs or replace the battery.
7. Connect the battery cable at the battery disconnect

switch.
8. Connect the positive battery cable of the battery.
9. Connect the negative battery cable of the battery. g00937676

Illustration 289
10. Install the key and turn the battery disconnect The belt assembly for the tier II engines is for the following serial
numbers: (S/N: MAB1-UP; PAB1-UP; FBA1-UP; GAA1-UP;
switch to the ON position. MAA1-UP; PAA1-UP; RAW1-UP; SBN1-UP)
156 SEBU7342-08
Maintenance Section
Belts - Inspect/Adjust/Replace
Your engine is equipped with a water pump, with

a fan drive, and with an alternator. Your engine
can also be equipped with an air conditioner belt.
For maximum engine performance and maximum
utilization of your engine, inspect the belts for wear
and for cracking. Check the belt tension. Adjust the
belt tension in order to minimize belt slippage. Belt
slippage will decrease the belt life. Belt slippage will
also cause poor performance of the alternator and
of any driven equipment.
If new belts are installed, recheck the belt adjustment

after 30 minutes of operation. If two belts or more are
required for an application, replace the belts in belt
sets. If only one belt of a matched set is replaced, the g00937677
new belt will carry more load. This is due to the fact Illustration 292
that the older belts are stretched. The additional load The belt assembly for the tier II engines is for the following serial
on the new belt could cause the new belt to break. numbers: (S/N: MAB1-UP; PAB1-UP; FBA1-UP; GAA1-UP;
MAA1-UP; PAA1-UP; RAW1-UP; SBN1-UP)
(1) Mounting bolt
Water Pump Belt, Fan Drive Belt, (2) Bracket bolt
(3) Adjusting bolt
and Alternator Belt
2. Apply approximately 98 N (22 lb) force midway
between the pulleys.
3. Measure the deflection of the belt. The belt should

deflect 10 to 12 mm (0.4 to 0.5 inch).
4. If the deflection is not correct, loosen alternator

mounting bolt (1) and bracket bolt (2). Turn
adjusting bolt (3) in order to adjust the belt tension.
5. When the adjustment is correct, tighten bolt (1)

and bolt (2).
6. Check the deflection of the belt again.

g00686313
Illustration 290
7. If a new belt is installed, run the engine at
1. Open the engine hood. rated speed for thirty minutes. Check the belt
adjustment. Readjust the belt, if necessary.
Air Conditioner Belt (If Equipped)

NOTICE
The V-belt must be tensioned correctly. Failure to ten-
sion the belt properly could cause damage to the belt
and/or to the air conditioner compressor.
g00688115
Illustration 291
The belt assembly for the tier I engines is for the following serial
numbers: (S/N: ANB1-UP; BCB1-UP; BDB1-UP; AMC1-UP;
BDC1-UP; CCD1-UP; ALF1-UP; AKH1-UP; BER1-UP)
(1) Mounting bolt
(2) Bracket bolt
(3) Adjusting bolt
SEBU7342-08 157
Maintenance Section
Boom Cylinder Head (Long Reach Configuration) - Lubricate
g00104278 g00685797
Illustration 293 Illustration 294
(4) Nut
(5) Adjusting bolt Apply lubricant through the fitting at the base of each
boom cylinder.
1. Apply approximately 100 N (22 lb) force midway
between the pulleys.
i01933858
2. Measure the deflection of the belt. The belt should

deflect 7 to 10 mm (0.3 to 0.4 inch).
Boom and Stick Linkage -
Lubricate
3. If the deflection is not correct, loosen nut (4). Turn
adjusting bolt (5) in order to adjust the belt tension. SMCS Code: 6501-086; 6502-086
4. When the adjustment is correct, tighten nut (4) to Note: Caterpillar recommends the use of 5%
a torque of 38 7 Nm (28 5 lb ft). molybdenum grease for lubricating the boom,
stick and bucket control linkage. Refer to Special
5. Check the deflection again. Publication, SEBU6250, Caterpillar Machine
Fluids Recommendations for more information on
Note: If a new belt is installed, check the belt molybdenum grease.
adjustment again after 30 minutes of engine
operation at the rated engine speed. Apply lubricant through all fittings after operation
under water.
6. Close the engine hood.
Wipe all fittings before you apply lubricant.
i01949843
Boom Cylinder Head (Long

Reach Configuration) -
Lubricate
SMCS Code: 5456-086-HE
S/N: ANB1-Up
Note: Caterpillar recommends the use of 5%

molybdenum grease for lubricating the boom,
stick and bucket control linkage. Refer to Special
Publication, SEBU6250, Caterpillar Machine g00685797
Illustration 295
molybdenum grease.
1. Apply lubricant through the fitting at the base of
Apply lubricant through all fittings after operation each boom cylinder.
under water.

158 SEBU7342-08
Maintenance Section
Boom, Stick and Bucket Linkage (Long Reach Configuration) - Lubricate
g00685798 g00685800
2. The fittings are at the base of the boom. The 6. Apply lubricant through fitting (7) on the stick
fittings can be serviced from the platform on top cylinder rod, fitting (8) at the connection point of
of the storage box. To lubricate the lower boom the boom and of the stick, and fitting (9) at the
bearings, apply lubricant through fittings (1) and bucket cylinder head end.
(2).
i01933871
3. Apply lubricant through fittings (3) and (4) for the
boom cylinder rod. Boom, Stick and Bucket
4. Apply lubricant through fitting (5) for the stick Linkage (Long Reach
cylinder head.
Configuration) - Lubricate
Note: To ensure proper lubrication of the lower
SMCS Code: 6501-086; 6502-086; 6513-086
boom bearings and of the boom cylinder rod end
bearings, lubricant should be applied through fittings S/N: ANB1-Up
(1), (2), (3), and (4). Apply lubricant first when the
boom is raised and any attachment is suspended. Note: Caterpillar recommends the use of 5%
Then apply lubricant when the boom is lowered and molybdenum grease for lubricating the boom,
the attachment is rested on the ground with a slight stick and bucket control linkage. Refer to Special
downward pressure. Publication, SEBU6250, Caterpillar Machine
molybdenum grease.
Apply lubricant through all fittings after operation

under water.
g00685799
Illustration 297
5. Apply lubricant through fitting (6). Fitting (6) is at

the connection point of the boom and of the stick.
g00685997
Illustration 299
SEBU7342-08 159
Maintenance Section
Bucket Linkage - Inspect/Adjust
1. Apply lubricant through fittings (1), (2), and (3) 7. Apply lubricant through fitting (13) for the stick
that are on the link. cylinder rod.
2. Apply lubricant through fittings (4), (5), and (6) 8. Apply lubricant through fitting (14) for the
that are on the bucket. connection of the boom and of the stick.
i02168785
Bucket Linkage -
Inspect/Adjust
SMCS Code: 6513-025; 6513-040
Unexpected machine movement can cause injury

or death.
Illustration 300
g00685999 To avoid possible machine movement, move the
hydraulic lockout control to the locked position
3. The fittings are at the base of the boom. The and attach a Special Instruction, SEHS7332, Do
fittings can be serviced from the platform on top Not Operate or similar warning tag to the hy-
of the storage box. To lubricate the lower boom draulic lockout control.
bearings, apply lubricant through fittings (7) and
(8).
NOTICE
Improperly adjusted bucket clearance could cause
4. Apply lubricant through fittings (9) and (10) for the
galling on the contact surfaces of the bucket and
boom cylinder rod.
stick, resulting in excessive noise and/or damaged
O-ring seals.
5. Apply lubricant through fitting (11) for the stick
cylinder head.
Note: To ensure proper lubrication of the lower boom

bearings and of the boom cylinder rod end bearings,
lubricant should be applied through fittings (7), (8),
(9), and (10). Apply lubricant first when the boom
is raised and any attachment is suspended. Then
apply lubricant when the boom is lowered and the
attachment is rested on the ground with a slight
downward pressure.
g00101687
Illustration 302
(1) No gap
(2) Stick boss
(3) Bucket clearance
(4) Shims
(5) Pin
(6) Plate
(7) Bolts
(8) Washers
(9) Location
(10) Flange
(11) Bucket boss
g00110105
Illustration 301
6. Apply lubricant through fitting (12) for the head

of the bucket cylinder.
160 SEBU7342-08
Maintenance Section
Bucket Linkage - Lubricate
The clearance of the bucket control linkage on 8. After installation, make sure that bucket clearance
this machine can be adjusted by shimming. If the (3) is still correct.
gap between the bucket and the stick becomes
excessive, adjust bucket clearance (3) to 0.5 to 1 mm
i01942324
(.02 to .04 inch).
Two shims of different thickness are used at location

Bucket Linkage - Lubricate
(9). The thicknesses of the shims are 0.5 mm SMCS Code: 6513-086
(0.02 inch ) and 1.0 mm (0.04 inch).
Note: Caterpillar recommends the use of 5%
molybdenum grease for lubricating the bucket
linkage. Refer to Special Publication, SEBU6250,
Caterpillar Machine Fluids Recommendations for
more information on grease.
g00102146
Illustration 303
Area for linkage adjustment
1. Position the machine on a level surface and lower

the bucket to the ground.
2. Slowly operate the swing control lever until stick

boss (2) and the bucket boss (11) are in full face Illustration 304
g00682908
contact at no gap (1). This will help to determine
the total clearance of the connection point of the Note: Completely fill all cavities of the bucket control
stick and of the bucket. linkage with grease when you initially install a bucket.
3. Place the hydraulic lockout control in the LOCKED 1. Apply lubricant through fittings for the linkages (1),
position and stop the engine. (2), (3), and (4).
4. Measure bucket clearance (3), which is the 2. Apply lubricant through fittings for the bucket (5),
existing total clearance. (6), and (7).
5. Determine the number of shims that need to be Note: Service the above fittings after you operate
removed from shims (4) by using the following the bucket under water.
calculation:
Subtract 0.5 mm (0.02 inch ) or 1.0 mm (0.04 inch)

from bucket clearance (3).
6. Remove the appropriate number of shims at

location (9) in order to meet the above thickness.
Make sure that you use a minimum of three
0.5 mm (0.02 inch) shims. To remove the shims,
remove bolts (7), washers (8), and plate (6).
7. After the correct number of shims has been

removed and pin (5) is aligned with the pin
hole, install plate (6), washers (8), and bolts (7).
Tighten bolts (7) to a torque of 240 40 Nm
(175 30 lb ft).
SEBU7342-08 161
Maintenance Section
Bucket Tips - Inspect/Replace
i02420545

SMCS Code: 6805-040; 6805-510
Block the bucket before changing the bucket

teeth.
To prevent possible injury to the eyes, wear a pro-

tective face shield when striking the pin.
The pin, when struck, can fly out and cause injury Illustration 306
g00590670
to nearby personnel.
(4) Back of Pin-Master
(5) Extractor
Bucket Tips a. Place the Pin-Master on the bucket tip.
b. Align extractor (5) with the pin.
c. Strike the Pin-Master at the back of the tool (4)

and remove the pin.
Note: Discard the old pin and the retainer assembly.

When you change tips, use a new pin and a new
retainer assembly. Refer to the appropriate parts
manual for your machine.
g00101352
Illustration 305
(1) Usable
(2) Replace this bucket tip.
(3) Overworn
Check the bucket tips for wear. If the bucket tip has a
hole, replace the bucket tip.
1. Remove the pin from the bucket tip. The pin can
be removed by one of the following methods.
g01194448
Illustration 307
Use a hammer and a punch from the retainer
side of the bucket to drive out the pin. (6) Retainer assembly
(7) Adapter
Use a Pin-Master. Follow Step 1.a through Step 2. Clean the adapter and the pin.
1.c for the procedure.
3. Fit retainer assembly (6) into the counterbore that
is in the side of adapter (7). Make sure that the
face of the retainer assembly with the marking
OUTSIDE is visible.
162 SEBU7342-08
Maintenance Section
g00101359 g01209140
(4) Back of Pin-Master
4. Install the new bucket tip onto the adapter. (9) Pin holder
(10) Pin setter
Note: The bucket tips can be rotated by 180 degrees
in order to allow the tip to wear evenly. You may also b. Place the Pin-Master over the bucket tips so
move the tips from the outside teeth to the inside that the pin will fit into the counterbore of the
teeth. Check the tips often. If wear is present on the pin holder (9).
tips, rotate the tips. The outside teeth generate the
most wear. c. Strike the Pin-Master with a hammer at the
back of the tool (4) in order to insert the pin.
5. Drive the pin through the bucket tip. The pin can
be installed by using one of the following methods: d. Slide pin holder (9) away from the pin and
rotate the tool slightly in order to align pin setter
From the same side of the retainer, drive the pin (10) with the pin.
through the bucket tip, the retainer assembly,
and the adapter.
Use a Pin-Master. Follow Step 5.a through Step

5.e for the procedure.
g01209159
Illustration 311
Final assembly of pin into bucket tip.
e. Strike the end of the tool until the pin is fully

inserted.
g01209166
Illustration 309
(8) Pin
a. Insert pin (8) through the bucket tip.

SEBU7342-08 163
Maintenance Section
Side Cutters
g01092812
Illustration 314
g01092808
Illustration 312 Section B-B From Illustration 313
Bucket With Side Cutters (A) Side cutter
(A) Side cutters (C) Shear ledge on a side cutter
(D) Side plate on a bucket
(E) 0.0 mm (0.0 inch)
1. Remove the mounting bolts and the side cutters.
5. Make sure that there is not a gap between the
2. Clean the mounting surface of the side plate on side plate on the bucket and the shear ledge on
the bucket and of the side cutter. Remove any the side cutter.
burrs or protrusions on the mating surfaces.
6. Torque the mounting bolts to the correct
specification.
Side Protectors
Inspect the wear of the side protector. When too
much wear is present, replace the protector.
g01092810
Illustration 313
(A) Side cutter
Note: Some side cutters may be rotated for additional

wear.
3. Install the side cutter.

g00851494
Illustration 315
Note: Certain bolts may require thread compound.
4. Hand tighten the bolts.

164 SEBU7342-08
Maintenance Section
Cab Air Filter (Fresh Air) - Clean/Replace
The fresh air filter is located behind the cab.
1. Loosen bolt (1) and open filter cover (2) and air
filter (3).
g00851496
Illustration 316
(11) Side protector
(12) Pin
(13) Retainer
(14) side plate g00686273
Illustration 318
1. Hit pin (12) from the retainer side of the bucket (2) Filter cover
(3) Air filter
in order to remove side protector (11) from side
plate (14).
2. Remove air filter (3) from filter cover (2).
2. Clean side protector (11), pin (12), retainer (13)
and side plate (14) before installation. 3. Clean the air filter with a maximum of 200 kPa
(30 psi) pressure air.
3. Put retainer (13) in side plate (14).
4. After you clean the air filter, inspect the air filter.
4. Align two pin holes of the new protector and the If the air filter is damaged or badly contaminated,
side plate. Hit the pin from the side of the bucket use a new air filter.
without the retainer.
5. Install the air filter and the filter cover.
Note: If the pin and/or the retainer are worn, replace
the pin and/or the retainer. Note: Make sure that the arrow on top of the air filter
is facing forward.
i01520852
i01295288
Cab Air Filter (Fresh Air) - Circuit Breakers - Reset
Clean/Replace
SMCS Code: 1420-529
SMCS Code: 7342-070; 7342-510
g00686291
Illustration 319
g00686272
Illustration 317
(1) Bolt
(2) Filter cover
SEBU7342-08 165
Maintenance Section
Condenser (Refrigerant) - Clean
Alternator Circuit This circuit breaker

is designed to protect the alternator. If the
batteries are installed with reversed polarity,
the circuit breaker would prevent the alternator from
damaging the rectifier.
The circuit breaker has a capacity of 60 Amp.
Circuit Breaker Reset Push in the button in order

to reset the circuit breaker. If the electrical system is
working properly, the button will remain depressed.
If the button does not remain depressed, check the
appropriate electrical circuit. Repair the electrical
circuit, if necessary. Illustration 321
g00537515
Typical example
i01041005
2. Inspect the condenser for debris. Clean the
Condenser (Refrigerant) - condenser, if necessary.
Clean 3. Use clean water to wash off all dust and dirt from
SMCS Code: 1805-070 the condenser.
4. Close the access door.

NOTICE
If excessively dirty, clean condenser with a brush. To
prevent damage or bending of the fins, do not use a i02582005
stiff brush.
Cooling System Coolant (ELC)
Repair the fins if found defective. - Change
SMCS Code: 1350-044
Personal injury can result from hot coolant, steam

and alkali.
At operating temperature, engine coolant is hot

and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to

g00102191 relieve pressure only when engine is stopped and
Illustration 320 cooling system pressure cap is cool enough to
touch with your bare hand.
1. Open the access door on the left side of the
machine. Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.

Avoid contact with skin and eyes.
166 SEBU7342-08
Maintenance Section
Cooling System Coolant (ELC) - Change
NOTICE
Do not change the coolant until you read and under-
stand the cooling system information in Special Pub-
lication, SEBU6250, Caterpillar Machine Fluids Rec-
ommendations.
Failure to do so could result in damage to the cooling

system components.
NOTICE
Mixing ELC with other products will reduce the effec-
tiveness of the coolant.
g00544378
This could result in damage to cooling system compo- Illustration 323
nents.
Note: Refer to Operation and Maintenance Manual,
If Caterpillar products are not available and com- General Hazard Information for information that
mercial products must be used, make sure they pertains to containing fluid spillage.
have passed the Caterpillar EC-1 specification for
pre-mixed or concentrate coolants and Caterpillar 4. Remove the access cover that is underneath the
Extender. radiator.
5. Open the drain valve and allow the coolant to

Note: This machine was filled at the factory with drain into a suitable container. The drain valve is
Caterpillar Extended Life Coolant. located on the bottom of the radiator.
If the coolant in the machine is changed to Extended 6. Flush the cooling system. Follow Step 6.a through
Life Coolant from another type of coolant, see Special Step 6.h in order to properly flush the cooling
Publication, SEBU6250, Caterpillar Machine Fluids system.
Recommendations.
a. Close the drain valve.
1. Unlatch the engine hood and raise the engine
hood. b. Fill the cooling system with clean water.
c. Install the pressure cap.
d. Start the engine and run the engine until the

engine reaches operating temperature.
e. Stop the engine and allow the engine to cool.
f. Loosen the pressure cap slowly in order to

relieve any pressure in the cooling system.
g. Open the drain valve that is underneath the

radiator and allow the coolant to drain into a
suitable container.
g00544510
Illustration 322
h. Flush the radiator with clean water until the
draining water is transparent.
2. Slowly loosen the pressure cap that is on the
radiator in order to release pressure from the
7. Close the drain valve and install the access cover
cooling system.
underneath the radiator.
3. Remove the pressure cap.
8. Add the Extended Life Coolant. Refer to the
following topics:
Special Publication, SEBU6250, Caterpillar

Machine Fluids Recommendations
SEBU7342-08 167
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
Operation and Maintenance Manual, Capacities i02586600

(Refill)
Cooling System Coolant
9. Start the engine. Operate the engine without
the cooling system pressure cap until the water
Extender (ELC) - Add
temperature regulator opens and the coolant level SMCS Code: 1352; 1353; 1395
stabilizes.
10. Maintain the coolant level within 13 mm (.5 inches)

of the bottom of the filler pipe.
11. Inspect the gasket of the cooling system pressure and alkali.
cap. If the gasket is damaged, replace the
pressure cap. At operating temperature, engine coolant is hot
12. Install the cooling system pressure cap. to heaters or the engine contain hot coolant or
13. Stop the engine.
Remove cooling system pressure cap slowly to
14. Open the left access door. relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when

burns.

Avoid contact with skin and eyes.
Use Caterpillar Extended Life Coolant (ELC) when

you add coolant to the cooling system. See Special
Publication, SEBU6250, Caterpillar Machine
Fluids Recommendations for all cooling system
g00545226 requirements.
Illustration 324
(1) FULL Use a Coolant Conditioner Test Kit in order to check
(2) LOW
the concentration of the coolant.
15. Check the coolant reservoir. Maintain the coolant
level between FULL mark (1) and LOW mark NOTICE
(2). Mixing ELC with other products will reduce the effec-
tiveness of the coolant.
16. If additional coolant is necessary, remove the
reservoir cap and add the appropriate coolant This could result in damage to cooling system compo-
solution. nents.
17. Install the reservoir cap. If Caterpillar products are not available and com-
mercial products must be used, make sure they
18. Close the engine hood and latch the engine hood. have passed the Caterpillar EC-1 specification for
Close the left access door. pre-mixed or concentrate coolants and Caterpillar
Extender.
Note: This machine was filled at the factory with

Caterpillar Extended Life Coolant.
1. Park the machine on level ground.
2. Stop the engine.

168 SEBU7342-08
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
3. Unlatch the engine hood and raise the engine i02250847

hood.
Sample (Level 1) - Obtain
SMCS Code: 1395-008; 1395-554; 7542
Note: It is not necessary to obtain a Coolant

Sample (Level 1) if the cooling system is filled
with Cat ELC (Extended Life Coolant). Cooling
systems that are filled with Cat ELC should have
a Coolant Sample (Level 2) that is obtained at
the recommended interval that is stated in the
Maintenance Interval Schedule.
Note: Obtain a Coolant Sample (Level 1) if the

g00544510 cooling system is filled with any other coolant
Illustration 325
instead of Cat ELC. This includes the following
types of coolants.
4. Make sure that the cooling system has cooled
down. Loosen the cooling system pressure
cap slowly in order to relieve system pressure. Commercial long life coolants that meet the
Caterpillar Engine Coolant Specification -1
Remove the pressure cap.
(Caterpillar EC-1)
General Hazard Information for information on Cat Diesel Engine Antifreeze/Coolant (DEAC)
containing fluid spillage.
Commercial heavy-duty coolant/antifreeze
5. It may be necessary to drain some coolant from
the radiator so that Caterpillar Extender can be NOTICE
added to the cooling system. Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Note: Always discard drained fluids according to Using the same pump for both types of samples may
local regulations. contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
6. Add Caterpillar Extended Life Coolant (ELC) to rect interpretation that could lead to concerns by both
the cooling system. Refer to the following topics dealers and customers.
for the proper amount of Caterpillar Extender:
Note: Level 1 results may indicate a need for
Special Publication, SEBU6250, Caterpillar Level 2 Analysis.
Operation and Maintenance Manual, Capacities NOTICE

(Refill) Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
7. Inspect the gasket of the cooling system pressure ing, adjusting and repair of the product. Be prepared to
cap. If the gasket is damaged, replace the collect the fluid with suitable containers before open-
pressure cap. ing any compartment or disassembling any compo-
nent containing fluids.
8. Install the cooling system pressure cap.
Refer to Special Publication, NENG2500, Caterpillar
9. Close the engine hood and latch the engine hood. Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and

mandates.
SEBU7342-08 169
Maintenance Section
i01901596

Sample (Level 2) - Obtain
SMCS Code: 1395-008; 1395-554; 7542
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.
g00811362
Illustration 326
A typical example is shown. Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
Obtain the sample of the coolant as close as possible suitable to collect and contain fluids on Caterpillar
to the recommended sampling interval. In order products.
to receive the full effect of SOS analysis, you
must establish a consistent trend of data. In order Dispose of all fluids according to local regulations and
to establish a pertinent history of data, perform mandates.
consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.
Use the following guidelines for proper sampling of

the coolant:
Complete the information on the label for the

sampling bottle before you begin to take the
samples.
Keep the unused sampling bottles stored in plastic

bags.
Obtain coolant samples directly from the coolant g00811362

sample port. You should not obtain the samples Illustration 327
from any other location. A typical example is shown.
Keep the lids on empty sampling bottles until you Obtain the sample of the coolant as close as possible
are ready to collect the sample. to the recommended sampling interval. Supplies
for collecting samples can be obtained from your
Place the sample in the mailing tube immediately Caterpillar dealer.
after obtaining the sample in order to avoid
contamination. Refer to Operation and Maintenance Manual,
Never collect samples from expansion bottles. for the guidelines for proper sampling of the coolant.
Never collect samples from the drain for a system. Submit the sample for Level 2 analysis.
Submit the sample for Level 1 analysis. Reference: For additional information about coolant
analysis, refer to Special Publication, SEBU6250,
For additional information about coolant analysis, see Caterpillar Machine Fluids Recommendations or
Special Publication, SEBU6250, Caterpillar Machine consult your Caterpillar dealer.
Fluids Recommendations or consult your Caterpillar
dealer.
170 SEBU7342-08
Maintenance Section
Cooling System Coolant Level - Check
i02580035
Cooling System Coolant Level

- Check
SMCS Code: 1350-535; 1395-535-FLV

and alkali.
At operating temperature, engine coolant is hot

g00544510
to heaters or the engine contain hot coolant or Illustration 329
b. Slowly loosen the cooling system pressure cap
Remove cooling system pressure cap slowly to in order to relieve system pressure. Remove
relieve pressure only when engine is stopped and the pressure cap.
cooling system pressure cap is cool enough to
touch with your bare hand. Note: Refer to Operation and Maintenance Manual,
General Hazard Information for information on
Do not attempt to tighten hose connections when containing fluid spillage.
burns. c. Add the appropriate coolant solution to the
cooling system. Refer to the following topics:
Avoid contact with skin and eyes. Special Publication, SEBU6250, Caterpillar
1. Open the left rear access door. Operation and Maintenance Manual,
Capacities (Refill)
d. Start the engine. Operate the engine without

the cooling system pressure cap until the water
temperature regulator opens and the coolant
level stabilizes.
e. Maintain the coolant level within 13 mm

(0.5 inch) of the bottom of the filler pipe.
f. Inspect the condition of the gasket on the

pressure cap. If the gasket is damaged, replace
the pressure cap.
g00545226 g. Install the cooling system pressure cap.

Illustration 328
(1) FULL level h. Stop the engine.
(2) LOW level
i. Close the engine hood and latch the engine

2. Check the coolant level of the coolant reservoir. hood.
Maintain the coolant level between the FULL
mark and the LOW mark. If the coolant reservoir Note: Refer to Operation and Maintenance Manual,
is empty, follow Steps 2.a through 2.i. General Hazard Information for information on
a. Unlatch the engine hood and raise the engine
hood. 3. If additional coolant is necessary, remove the
reservoir cap and add the appropriate coolant
solution.
4. Install the reservoir cap.

SEBU7342-08 171
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
5. Close the left access door.
i02530911
Engine Air Filter Primary

Element - Clean/Replace
SMCS Code: 1054-070; 1054-510
If a warning and a pictograph is displayed on the

message display or if the exhaust is black, check the
primary filter.
1. Open both access doors on the left side of the g00101415

machine. Illustration 332
4. Remove the primary filter element from the air

cleaner housing.
5. Clean the air cleaner cover and the inside of the

air cleaner housing.
6. Inspect the O-ring seal on the air cleaner cover.

Replace the O-ring seal if the O-ring seal is worn
or damaged.
7. Install the clean primary filter.
Note: Refer to Cleaning Primary Air Filter Elements.

g01266485
Illustration 330 8. Install the air cleaner cover and close the latches
securely.
2. Squeeze the outlet tube (1) slightly in order to
purge the dirt from the outlet tube.
g00101416
Illustration 333
g01266486
Illustration 331 Note: Install the air cleaner cover properly. The
arrows must point upward.
3. Loosen the cover latches (2) and remove the air
cleaner cover. 9. Change the filter if any of the following conditions
occurs:
Restricted Air Filter indicator on the monitor

panel still comes on.
Exhaust smoke is still black after the installation

of a primary filter.
172 SEBU7342-08
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
10. Close the access doors. Pressurized Air

Pressurized air can be used to clean primary air filter
Cleaning Primary Air Filter elements that have not been cleaned more than two
Elements times. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum
NOTICE pressure of 207 kPa (30 psi).
Caterpillar recommends certified air filter cleaning ser-
vices available at participating 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:
Do not tap or strike the filter element in order to re-

move dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove

the dust from the filter element. Air pressure must not g00281692
exceed 207 kPa (30 psi). Direct the air flow up the Illustration 334
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage Note: When the primary air filter elements are
to the pleats. cleaned, always begin with the clean side (inside)
in order to force dirt particles toward the dirty side
Do not use air filters with damaged pleats, gaskets, or (outside).
seals. Dirt entering the engine will cause damage to
engine components. Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent
damage to the paper pleats. Do not aim the stream of
When the primary air filter element is cleaned, check air directly at the primary air filter element. Dirt could
for rips or tears in the filter material. Replace the be forced further into the pleats.
primary air filter element after the primary air filter
element has been cleaned six times. The primary air Vacuum Cleaning
filter element should be replaced at least one time
per year. This replacement should be performed Vacuum cleaning is another method for cleaning
regardless of the number of cleanings. primary air filter elements which require daily cleaning
because of a dry, dusty environment. Cleaning with
NOTICE pressurized air is recommended prior to vacuum
Do not clean the air filter elements by bumping or tap- cleaning. Vacuum cleaning will not remove deposits
ping. This could damage the seals. Do not use ele- of carbon and oil.
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.
There are two common methods that are used to

clean primary air filter elements:
Pressurized air
Vacuum cleaning
SEBU7342-08 173
Maintenance Section
Engine Air Filter Secondary Element - Replace
Inspecting the Primary Air Filter Do not use paint, a waterproof cover, or plastic as a
protective covering for storage. An air flow restriction
Elements may result. To protect against dirt and damage, wrap
the primary air filter elements in Volatile Corrosion
Inhibited (VCI) paper.
Place the primary air filter element into a box for

storage. For identification, mark the outside of the
box and mark the primary air filter element. Include
the following information:
Date of cleaning
Number of cleanings
Store the box in a dry location.
g00281693
Illustration 335
i01430699
Inspect the clean, dry primary air filter element. Use Engine Air Filter Secondary
a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air filter Element - Replace
element. Rotate the primary air filter element. Inspect
the primary air filter element for tears and/or holes. SMCS Code: 1054-510
Inspect the primary air filter element for light that may
show through the filter material. If it is necessary in NOTICE
order to confirm the result, compare the primary air Always replace the secondary filter element. Never at-
filter element to a new primary air filter element that tempt to reuse the secondary filter element by clean-
has the same part number. ing the element.
Do not use a primary air filter element that has any When the primary filter element is replaced, the sec-
tears and/or holes in the filter material. Do not use ondary filter element should be replaced.
a primary air filter element with damaged pleats,
gaskets or seals. Discard damaged primary air filter The secondary filter element should also be replaced
elements. if the air filter restriction warning appears on the mes-
sage display after the installation of a clean primary
Storing Primary Air Filter Elements filter element or if exhaust smoke is still black.
If a primary air filter element that passes inspection 1. Open the access door on the front left side of the
will not be used, the primary air filter element can machine.
be stored for future use.
2. See Operation and Maintenance Manual, Engine
Air Filter Primary Element - Clean/Replace.
Remove the air cleaner cover from the air cleaner
housing. Remove the primary filter element from
the air cleaner housing.
g00281694
Illustration 336
174 SEBU7342-08
Maintenance Section
Engine Crankcase Breather - Clean
3. Remove breather (3) and O-ring seal (4).
4. Wash breather (3) in clean, nonflammable solvent.
5. Inspect O-ring seal (4). If the seal is damaged,

install a new seal.
6. Install O-ring seal (4) and clean breather (3).
7. Slide outlet hose (1) on breather (3). Tighten hose

clamp (2).
g00101451
Illustration 337 i03026880
3. Remove the secondary filter element. Engine Oil Level - Check

4. Cover the air inlet opening. Clean the inside of SMCS Code: 1000-535
the air cleaner housing.
NOTICE
5. Remove the cover from the air inlet opening. Do not overfill the crankcase. Engine damage can re-
sult.
6. Install the new secondary filter element.
Note: This machine is equipped with both an
7. Install the primary filter element. automated function for checking fluid levels and
a dipstick. Refer to Operation and Maintenance
8. Install the air cleaner cover and close the latches Manual, Monitoring System regarding the
securely. automated system. If the machine is on an incline or
the engine has been stopped only for a short time,
9. Close the access door. then the engine oil does not return to the crankcase
and the fluid level cannot be properly checked by
i01584904 either method. Park the machine on level ground and
check the oil level after the engine has been stopped
Engine Crankcase Breather - for at least 30 minutes.
Clean Check the oil level while the engine is stopped. Do
not check the oil level while the engine is running.
SMCS Code: 1317-070-DJ
1. Open the hood.
1. Open the engine hood.
g00824182
g00824179 Illustration 339
Illustration 338
This tier I engine pertains to the following serial numbers: (S/N:
ANB1-UP; BDB1-UP; AMC1-UP; BCB1-UP; BDC1-UP; CCD1-UP;
2. Loosen hose clamp (2) and disconnect outlet hose ALF1-UP; AKH1-UP; BER1-UP)
(1) from breather (3).
SEBU7342-08 175
Maintenance Section
Engine Oil Level - Check
g00937619 g00824183
This tier II engine pertains to the following serial numbers: (S/N: This tier I engine pertains to the following serial numbers: (S/N:
MAB1-UP; PAB1-UP; FBA1-UP; GAA1-UP; MAA1-UP; PAA1-UP; ANB1-UP; BCB1-UP; BDB1-UP; AMC1-UP; BDC1-UP; CCD1-UP;
RAW1-UP; SBN1-UP) ALF1-UP; AKH1-UP; BER1-UP)
2. Remove the dipstick. Wipe the oil off the dipstick

and insert the dipstick.
g00937631
Illustration 343
This tier II engine pertains to the following serial numbers: (S/N:
MAB1-UP; PAB1-UP; FBA1-UP; GAA1-UP; MAA1-UP; PAA1-UP;
g00824185 RAW1-UP; SBN1-UP)
Illustration 341
3. Remove the dipstick and check the dipstick. The Note: Refer to Operation and Maintenance Manual,
oil level should be between the H mark and the General Hazard Information for information on
L mark. Containing Fluid Spillage.
NOTICE 4. Remove the oil filler plug in order to add oil,

Operating your engine when the oil level is above the if necessary. See Operation and Maintenance
H mark could cause the crankshaft to dip into the oil. Manual, Capacities (Refill).
This could lead to excessively high oil temperatures
which can reduce the lubricating characteristics of the Note: If the oil is deteriorated or badly contaminated,
oil, lead to bearing damage, and could result in loss of change the oil regardless of the maintenance interval.
engine power.
5. Clean the oil filler plug. Install the oil filler plug.
6. Close the hood.

176 SEBU7342-08
Maintenance Section
Engine Oil Sample - Obtain
i01870159
Engine Oil Sample - Obtain

SMCS Code: 1000-008; 1000; 1348-008;
1348-554-SM; 7542-008; 7542-554-OC, SM
g00101627
Illustration 345
1. The drain valve for the engine crankcase oil is

located under the rear of the upper structure.

g00750336
Illustration 344 General Hazard Information for information on
Containing Fluid Spillage.
Obtain a sample of the engine oil from the engine oil
sampling valve that is located on the engine oil filter
housing. Refer to Special Publication, SEBU6250,
SOS Oil Analysis for information that pertains to
obtaining a sample of the engine oil. Refer to Special
Publication, PEHP6001, How To Take A Good Oil
Sample for more information about obtaining a
sample of the engine oil.
i03024547
Engine Oil and Filter - Change

SMCS Code: 1318-510
g00107915
Note: If the sulfur content in the fuel is greater than Illustration 346
1.5% by weight, use an oil that has a TBN of 30 and The crankcase drain valve for the tier I engine is located on the
following serial numbers: (S/N: ANB1-UP; BCB1-UP; BDB1-UP;
reduce the oil change interval by one-half.
AMC1-UP; BDC1-UP; CCD1-UP; ALF1-UP; AKH1-UP; BER1-UP)
Park the machine on a level surface and engage the

parking brake. Stop the engine.
Note: Drain the crankcase while the oil is warm. This

allows waste particles that are suspended in the oil to
drain. As the oil cools, the waste particles will settle
to the bottom of the crankcase. The particles will not
be removed by draining the oil and the particles will
recirculate in the engine lubrication system with the
new oil.
g00937651
Illustration 347
The crankcase drain valve for the tier II engine is located on the
following serial numbers: (S/N: MAB1-UP; PAB1-UP; FBA1-UP;
GAA1-UP; MAA1-UP; PAA1-UP; RAW1-UP; SBN1-UP)
SEBU7342-08 177
Maintenance Section
Engine Oil and Filter - Change
2. Open the crankcase drain valve. Allow the oil to

drain into a suitable container.
Note: Discard any drained fluids according to local

regulations.
3. Close the drain valve.
g00686496
Illustration 349
The tier I engine pertains to the following serial numbers: (S/N:
ANB1-UP; BCB1-UP; BDB1-UP; AMC1-UP; BDC1-UP; CCD1-UP;
ALF1-UP; AKH1-UP; BER1-UP)
(3) Dipstick
(4) Oil filler plug
g00686495
Illustration 348
(1) Drain valve
(2) Engine oil filter
5. Open drain valve (1). The drain valve is located

on the bottom of engine oil filter (2). Allow the
remaining oil in the filter to drain into a suitable
container.
6. Close drain valve (1). Tighten the locknut to

40 5 Nm (30 4 lb ft).
g00937661
Illustration 350
7. Remove oil filter (2). See Operation and
Maintenance Manual, Oil Filter - Inspect. Discard The tier II engine pertains to the following serial numbers: (S/N:
MAB1-UP; PAB1-UP; FBA1-UP; GAA1-UP; MAA1-UP; PAA1-UP;
the used oil filter properly. RAW1-UP; SBN1-UP)
(3) Dipstick
8. Clean the filter housing base. Make sure that all of (4) Oil filler plug
the former filter gasket is removed.
11. Remove oil filler plug (4). Fill the crankcase
9. Apply a thin coat of engine oil to the gasket of with new oil. See Operation and Maintenance
the new filter. Manual, Capacities (Refill) and Operation and
Maintenance Manual, Lubricant Viscosities.
10. Install the new filter by hand. When the gasket Clean the oil filler plug and install the oil filler plug.
contacts the filter base, turn the filter by 3/4 of a
turn more. This will tighten the filter sufficiently.
NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
12. Start the engine and allow the oil to warm. Check
the engine for leaks. Stop the engine.
178 SEBU7342-08
Maintenance Section
Engine Valve Lash - Check
g00104116 g00822278
(1) Oil level plug
13. Wait for 30 minutes in order to allow the oil to (2) Oil drain plug
drain back into the crankcase. Check the oil level
with dipstick (3). Maintain the oil between the H 1. Position one final drive so that oil drain plug (2) is
and L marks on the dipstick. If necessary, add oil. at the bottom.
14. Close the engine hood. Note: Refer to Operation and Maintenance Manual,
i01747875
Engine Valve Lash - Check 2. Remove drain plug (2) and level plug (1). Allow
the oil to drain into a suitable container.
SMCS Code: 1102-082; 1102-535; 1102; 1105-025;
1105-535; 1121-535; 1209-082; 1209-535; 1209; 3. Clean the plugs and inspect the O-ring seals. If
7527 wear or damage is evident, replace the drain plug,
the level plug, and/or the O-ring seals.
Refer to Engine Systems Operation/Testing and
Adjusting in order to perform the complete procedure 4. Install drain plug (2).
for the valve lash adjustment.
5. Fill the final drive to the bottom of the opening on
level plug (1). See Operation and Maintenance
i02580062 Manual, Lubricant Viscosities and Operation and
Maintenance Manual, Capacities (Refill) .
Final Drive Oil - Change
6. Install level plug (1).
SMCS Code: 4050-044-FLV
7. Perform Step 1 to Step 6 on the other final drive.
Use a different container for the oil so that the oil
samples from the final drives will be separate.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to 8. Completely remove the oil that has spilled onto
contact skin. surfaces.
9. Start the engine and allow the final drives to run

through several cycles.
10. Stop the engine. Check the oil level.
11. Check the drained oil for metal chips or for

particles. If there are any chips or particles, consult
your Caterpillar dealer.
12. Properly dispose of the drained material. Obey

local regulations for the disposal of the material.
SEBU7342-08 179
Maintenance Section
Final Drive Oil Level - Check
i02580064 i02580071
Final Drive Oil Level - Check Final Drive Oil Sample - Obtain
SMCS Code: 4050-535-FLV SMCS Code: 4011-008; 4050-008; 4050-SM;
7542-008

injury. Do not allow hot oil or hot components to Hot oil and hot components can cause personal
contact skin. injury. Do not allow hot oil or hot components to
contact skin.
g00822278
Illustration 353
g00822278
(1) Oil level plug Illustration 354
(2) Oil drain plug (1) Oil level plug
(2) Oil drain plug
1. Position one final drive so that oil drain plug (2) is
at the bottom. 1. Position the final drive so that oil drain plug (2) is
at the bottom.
General Hazard Information for information on Note: Refer to Operation and Maintenance Manual,
Containing Fluid Spillage. General Hazard Information for information on
2. Remove oil level plug (1).
2. Remove oil level plug (1).
3. Check the oil level. The oil should be near the
bottom of the level plug opening. 3. Obtain a sample of the final drive oil through the
hole for the oil level plug.
4. Add oil through the level plug opening, if
necessary. See Operation and Maintenance, 4. Install oil level plug (1).
Lubricant Viscosities.
Refer to Special Publication, SEBU6250, Caterpillar
Note: Overfilling the final drive will cause the seals on Machine Fluids Recommendations, SOS Oil
the travel motor to allow hydraulic oil or water to enter Analysis for more information on obtaining a sample
the final drive. This may contaminate the final drive. of the final drive oil. For additional information about
taking an oil sample, refer to Special Publication,
5. Clean oil level plug (1). Inspect the O-ring seal. PEHP6001, How To Take A Good Oil Sample.
Replace the O-ring seal if the O-ring seal is worn
or damaged.
i01516680
6. Install oil level plug (1). Fuel Inlet Screen - Clean

7. Repeat the procedure for the other final drive. SMCS Code: 1263
Open the access door on the left side of the machine.

180 SEBU7342-08
Maintenance Section
Fuel System Filter - Replace
Check the inlet screen of water separator. If foreign 6. Replace the inlet screen into the water separator
particles are found, clean the inlet screen. Use Step 1 base.
through Step 8 in order to clean the fuel inlet screen.
7. Replace filter case (3) and screen holder (4).
Tighten ring nut (2).
i02582070
Fuel System Filter - Replace

SMCS Code: 1261-510
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.
NOTICE
g00666109 Turn the disconnect switch OFF or disconnect the bat-
Illustration 355
tery when changing fuel filters.
(1) Drain valve
(2) Ring nut
(3) Filter case Do not fill fuel filters with fuel before installing them.
(4) Screen holder Contaminated fuel will cause accelerated wear to fuel
(5) Inlet screen systems parts.
(6) O-ring
1. Loosen drain valve (1) of the water separator and 1. Open the engine hood.
drain the water into a suitable container.
Note: Refer to Operation and Maintenance Manual, General Hazard Information for information on
General Hazard Information for information on containing fluid spillage.
Note: Dispose of drained fluids according to local

regulations.
2. Loosen ring nut (2). Remove filter case (3) and

screen holder (4).
3. Remove inlet screen (5) from the water separator

base.
4. Clean inlet screen (5) by using a clean,

nonflammable solvent.
5. Check O-ring (6). If the O-ring is damaged, replace g00686799

the O-ring. Illustration 356
2. Remove the filter.

SEBU7342-08 181
Maintenance Section
Fuel System - Prime
Note: Always discard used filters according to local

regulations.
3. Clean the filter mounting base. Make sure that all

of the old filter seal is removed.
4. Apply clean diesel fuel to the seal of the new fuel

filter.
5. Install the new fuel filter hand tight until the seal of
the fuel filter contacts the filter mounting base.
Note: Instructions for the installation of the filter are

printed on the side of each Caterpillar spin-on filter.
For non-Caterpillar filters, refer to the installation g00686839
instructions that are provided by the supplier of the Illustration 357
filter. (1) Air vent
(2) Priming pump plunger
(3) Air vent
Note: You may need to use a Caterpillar strap
wrench, or another suitable tool, in order to turn
the filter to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filter.
2. Loosen air vent (1) on the fuel filter.
6. Prime the fuel system. See Operation and
Maintenance Manual, Fuel System - Prime for
3. Rotate priming pump plunger (2) in a
instructions.
counterclockwise rotation. Rotate the plunger
until the plunger becomes unlocked. Operate the
priming pump plunger.
i02582065 4. Tighten air vent (1) when the fuel flow is free of
air bubbles.
Fuel System - Prime
5. Loosen air vent (3) on the fuel injector pump.
SMCS Code: 1250-548
6. Operate priming pump plunger (2). Allow the fuel
to flow until the fuel is free of air bubbles.
Personal injury or death may result from failure to 7. Push the plunger inward and rotate the plunger
adhere to the following procedures. clockwise. This motion will lock the plunger in
place.
cal components can cause a fire. 8. Tighten vent plug (3) on the fuel injection pump.
Clean up all leaked or spilled fuel. Do not smoke Note: Lock the priming pump plunger before vent
while working on the fuel system. plug (3) is tightened. Pressure in the fuel system
could make locking the plunger in place difficult.
Turn the disconnect switch OFF or disconnect the
battery when changing fuel filters. i01430725

Fuel System Water Separator
- Drain
SMCS Code: 1263
1. Open the front access door on the left side of the

machine.
182 SEBU7342-08
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
NOTICE
Do not fill the fuel filters with fuel before installing the
fuel filters. The fuel will not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
ated wear to fuel system parts.
1. Open the front access door on the left side of the

machine.
g00686991
Illustration 358
2. Turn the drain valve counterclockwise in order to

open the drain valve.

3. Drain the water and drain the sediment into a

g00687097
suitable container. Illustration 359
(1) Collar
Note: Dispose of drained fluids according to local (2) Water separator element
regulations. (3) Collar
(4) Drain valve
(5) Bowl
4. Close the drain valve.
2. Turn drain valve (4) counterclockwise in order to
5. Close the access door. open the drain valve. The drain valve is on the
bottom of the water separator.
i02061928
Fuel System Primary Filter General Hazard Information for information that
pertains to containing fluid spillage.
(Water Separator) Element -
Replace 3. Drain the water and the sediment into a suitable
container.
SMCS Code: 1263-510-FQ
Note: Dispose of used fluids according to local
regulations.
4. Close drain valve (4).

Personal injury or death may result from failure to
adhere to the following procedures. 5. Hold the bottom of water separator element (2)
while you loosen collar (3).
cal components can cause a fire. 6. Remove bowl (5).
Clean up all leaked or spilled fuel. Do not smoke 7. Loosen collar (1).
while working on the fuel system.
8. Remove water separator element (2). Discard
Turn the disconnect switch OFF or disconnect the water separator element (2).
battery when changing fuel filters.
Note: The water separator element is a cartridge
type filter. The filter cannot be reused.
9. Clean the inside surfaces of the filter head and

of the bowl (5).
SEBU7342-08 183
Maintenance Section
Fuel Tank Cap and Strainer - Clean
10. Inspect the O-ring on bowl (5). Also inspect the

seal on the filter head. Replace these seals if the
seals are worn or damaged.
11. Install a new water separator element. Tighten

collar (1) in order to secure the water separator
element.
12. Install bowl (5). Tighten collar (3).
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.
g00824196
13. Close the access door. Illustration 361

i01589598 General Hazard Information for information on
Fuel Tank Cap and Strainer -
Clean 4. Remove the strainer that is located in the filler
opening.
SMCS Code: 1273-070-STR
5. Wash the strainer and the fuel tank cap in a clean,
nonflammable solvent.
6. Install a new cap filter kit. Install the gaskets, drain

valve (3), filter assembly (2), and screws (1).
7. Install the strainer into the filler opening.
8. Install the fuel tank cap.
i03024550
Fuel Tank Water and Sediment

g00824193
- Drain
Illustration 360
SMCS Code: 1273-543
1. Remove the fuel cap.
The fuel tank drain valve is located underneath the
2. Inspect seal (4) for damage. Replace the seal, if fuel tank.
necessary.
3. Remove screws (1), filter assembly (2), drain

valve (3) and the gaskets.
184 SEBU7342-08
Maintenance Section
Fuses - Replace
2. Close the drain valve by turning the valve

clockwise.
Fill the Fuel Tank

You can now add fuel to the fuel tank, if necessary.
Remove the fuel tank cap and pump fuel through the
opening.
Make sure that you lock the fuel tank cap after the
refueling is complete.
i01835389
Illustration 362
g00824198
Fuses - Replace
(S/N: ANB1-3815)
(S/N: MAB1-403) SMCS Code: 1417-510
(S/N: PAB1-1660)
(S/N: AMC1-3757)
(S/N: BDC1-UP)
(S/N: CCD1-UP)
(S/N: BER1-UP)
(S/N: RAW1-UP)
(S/N: SBN1-UP)
The fuel tank drain valve is located underneath the

main hydraulic pump.
g00101721
Illustration 364
Open the front access cover on the left side of the

machine.
g01043694
Illustration 363
(S/N: AMC3758-UP)
(S/N: ANB3816-UP)
(S/N: MAB404-UP)
(S/N: PAB1661-UP)
Note: Refer to Operation and Maintenance Manual, Illustration 365

g00687146
containing fluid spillage. The fuse panel is located on the circuit breaker panel.
Open the access cover for fuse access.
1. Open the drain valve by turning the valve
counterclockwise. Allow the water and the Fuses Fuses protect the electrical
sediment to drain into a suitable container. system from damage that is caused by
overloaded circuits. Change a fuse if the
Note: Dispose of drained fluids according to local element separates. If the element of a new fuse
regulations. separates, check the circuit and/or repair the circuit.
SEBU7342-08 185
Maintenance Section
Fuses - Replace
Spare (3) 10 Amp

NOTICE
Always replace fuses with the same type and capacity Spare (4) 15 Amp
fuse that was removed. Otherwise, electrical damage
could result. Spare (5) 15 Amp
Spare (6) 30 Amp

NOTICE
If it is necessary to replace fuses frequently, an elec- Heater and Air Conditioner Blower Fan (If
trical problem may exist. Equipped) (7) 15 Amp
Contact your Caterpillar dealer. Timer Relay (8) 10 Amp
To replace a fuse, use the puller that is stored in the Horn (9) 10 Amp
fuse panel. Three fuses of 5 Amperes, five fuses of
10 Amperes, two fuses of 15 Amperes, and one fuse Cab Light (If Equipped) (10) 10 Amp
of 30 Amperes are contained in the fuse panel as
spare fuses. Cab Dome Light and Radio Memory (11) 10 Amp
The following list identifies the circuits that are Engine Start Switch (12) 10 Amp
protected by each fuse. The amperage for each fuse
is included with each circuit. Engine Controller or Pump Controller (13) 10
Amp
Boom Light (14) 10 Amp
Controller for Attachment Valve (If Equipped)

(15) 15 Amp
Spare (16) 15 Amp
Product Link(17) 5 Amp
Electric Refueling Pump (If Equipped) (18) 30

Amp
Air Conditioner (If Equipped) or Cab Heater (19)

15 Amp
Radio (If Equipped) and Switch Panel (20) 5

Amp
Window Washer and Window Wiper (21) 10 Amp
Lower Window Washer (If Equipped) and Lower

Window Wiper (If Equipped) (22) 10 Amp
Backup Switches and Monitor Controller (23)

5 Amp
Cigar Lighter (24) 10 Amp
Chassis Light (25) 10 Amp
Seat Heater (If Equipped) (26) 5 Amp
12 Volt 7 Amp Converter 1 (27) 10 Amp

g00937670
Illustration 366
12 Volt 7 Amp Converter 2 (28) 10 Amp
Spare (1) 5 Amp
Attachment Solenoid (29) 10 Amp
Spare (2) 10 Amp
186 SEBU7342-08
Maintenance Section
Hydraulic System Oil - Change
Quick Coupler (If Equipped) (30) 5 Amp MTO

Power Window (If Equipped) (31) 15 Amp Commercial Oils
Alternator Regulator (32) 5 Amp Diesel engine oils (Heavy Duty) with a minimum
zinc content of 900 ppm can be used. Acceptable
Cab Fan (If Equipped) (33) 5 Amp commercial oils are identified by the American
Petroleum Institute trademark (API) . Refer to the list
Auxiliary Circuit (Attachment) (34) 10 Amp that follows for acceptable types of hydraulic oils.
Spare (35) 5 Amp CF

Spare (36) 5 Amp CF-4
Spare (37) 10 Amp CG-4
Spare (38) 10 Amp CH-4
Note: Industrial hydraulic oils are not recommended
i01835390
for the hydraulic systems of Caterpillar machines.
Hydraulic System Oil - Change Industrial hydraulic oils are more likely to allow
corrosion and Industrial hydraulic oils are more likely
SMCS Code: 5056-044 to allow excessive wear.
4000 Hour Oil Change Interval Procedure to Change the Hydraulic

Oil
A 4000 hour maintenance interval for hydraulic
oil (change) is available. The extended interval
requires SOS monitoring of the hydraulic oil. The
interval for SOS monitoring is every 500 hours. The
maintenance interval for the hydraulic oil filter is not
changed. If SOS monitoring is not performed, the
2000 hour maintenance interval must be used.
Machines with hammers are not included in the

4000 hour maintenance interval. Machines with
hammers must use the intervals that are listed in
the Maintenance Interval Schedule. Machines that
are used in severe conditions are not included in the
4000 hour maintenance interval. Machines that are
used in severe conditions must use the interval in the
g00101435
Maintenance Interval Schedule. Illustration 367
Lubricants 1. Park the machine on level ground. Lower the

bucket to the ground so that the stick is vertical.
Approved hydraulic oil must be used to obtain the
4000 hour hydraulic oil change. Refer to the list that
follows for approved oils.
Caterpillar Hydraulic Oils
Cat HYDO
TDTO
TDTO (TMS)
DEO
Biodegradable Hydraulic Oil (HEES)
SEBU7342-08 187
Maintenance Section
g00101446
Illustration 370
The oil drain valve is located under the hydraulic tank.
5. Remove the hydraulic tank access cover that is

located under the upper structure. This will allow
access to the drain valve.
g00687272
Illustration 368
2. Remove bolts (1), washers (2) and cover (3) from

the top of the hydraulic tank.
g00687273
Illustration 371
(4) Plug

Illustration 369
g00687312 General Hazard Information for information that
pertains to containing fluid spillage.
3. Clean the area thoroughly in order to keep dirt out
of the screen cover. Clean the area thoroughly in 6. Remove plug (4).
order to keep dirt out of the fill/vent plug.
4. Relieve the internal pressure from the hydraulic

tank by loosening the fill/vent plug. After the
pressure is relieved, remove the fill/vent plug.
188 SEBU7342-08
Maintenance Section
15. Remove the plug from the tube. Allow the oil to
drain into a container.
Note: Dispose of used filters and used fluids

according to local regulations.
16. Inspect the O-ring. Replace the O-ring if wear or

damage is evident.
17. Clean the plug. Install the plug and the O-ring into
the drain port.
g00687274
Illustration 372
(5) Pipe Nipple
(6) Hose
(7) Drain plug
7. Install a 3B-7271 Pipe Nipple (5) with hose (6)

into the hole on the bottom of the hydraulic tank.
8. Loosen drain plug (7) in order to drain the oil.
9. Drain the oil into a suitable container.

g00687277
Illustration 374
10. After the oil has been drained, tighten drain plug
(8) Bolts
(7) to a torque of 110 15 Nm (81 11 lb ft). (9) Washers
(10) Cover
11. Remove Pipe Nipple (5) and hose (6). (11) Spring
(12) Screen
12. Clean plug (4) and install the plug. Tighten the
plug to a torque of 75 5 Nm (55 48 lb ft). 18. Remove bolts (8), washers (9) and cover (10).
13. Open the access door on the right side of the Note: Dispose of used filters and used fluids
machine. according to local regulations.
14. Clean the pump, the hydraulic lines, and the Note: Do not allow spring (11) to fall back into the
hydraulic tank. tank.
19. Remove spring (11) and screen (12).
Note: Refer to Operation and Maintenance, General

Hazard Information for information on containing
fluid spillage.
20. Wash the screen in a clean nonflammable solvent.

Allow the screen to dry. Inspect the screen.
Replace the screen, if the screen is damaged.
g00687275
Illustration 373
SEBU7342-08 189
Maintenance Section
g00687278 g00687281
(13) O-ring seal
(14) O-ring seal 27. Remove the pressure cap.
21. Remove O-ring seal (13) from the screen. 28. Inspect the pressure cap. Clean the pressure cap.
Replace the pressure cap if damage is evident.
22. Inspect O-ring seals (13) and (14). Replace the
O-ring seals if wear or damage is evident. 29. Replace the pressure cap.
23. Install O-ring seal (13) on screen (12).
24. Install screen (12) and spring (11). Then install

cover (10), washers (9), and bolts (8).
Note: Make sure that the O-ring seals and the spring
are properly positioned during installation.
25. Fill the hydraulic system oil tank. Refer to

Operation and Maintenance Manual, Refill
Capacities.
g00753020
Illustration 378
(15) Drain hose
(16) Connector
(17) Seal
(18) Negative flow control hose
Note: Make no attempt to start the engine until the

pump has been filled with hydraulic oil. Serious
damage to the hydraulic components can result.
30. When the hydraulic oil has been replaced, the air
must be removed from the hydraulic oil system.
Illustration 376
g00687312 To remove the air from the hydraulic oil system,
follow Step 30.a through Step 30.g.
26. Inspect the O-ring seal on the filler plug for
damage. Replace the O-ring, if necessary. Clean a. While the engine is stopped, remove drain
the filler plug. Install the filler plug. hose (15), connector (16) and seal (17) from
the top of the pump. Add hydraulic oil through
the opening.
b. Check the condition of seal (17). If the seal is

damaged, replace the seal.
190 SEBU7342-08
Maintenance Section
Hydraulic System Oil Filter (Case Drain) - Replace
c. After the pump has been filled with oil, install 32. Operate the joysticks in order to circulate the
drain hose (15), connector (16) and seal (17) to hydraulic oil. Lower the bucket to the ground so
the original locations. that the stick is vertical to the ground. Stop the
engine.
d. Start the engine. When the engine is at low
idle, fully raise the boom. Hold the boom in this
position.
e. Slowly loosen negative flow control hose (18)

until the air has been released from the pump.
f. Tighten negative flow control hose (18).
g. Stop the engine. Slowly lower the boom until

the bucket is on the ground. This pressurizes
the hydraulic tank.
g00687286
Illustration 381
33. Maintain the oil level between the marks on the

sight gauge in the appropriate temperature range.
i02232800
Hydraulic System Oil Filter

(Case Drain) - Replace
g00687285
Illustration 379
(19) Vent plug SMCS Code: 5068-510; 5091-510
h. Slowly loosen vent plug (19) until the hydraulic

oil flows out of the opening. This indicates that
the air has been released from the pump.
i. Tighten vent plug (19).
31. Start the engine. Operate the engine at idling

speed for five minutes.
g00101435
Illustration 382
1. Park the machine on level ground. Lower the

g00101435
Illustration 380
SEBU7342-08 191
Maintenance Section
g00811329 g00101497
2. Move the lever for the hydraulic lockout control to 8. Open the access door on the right side of the
the UNLOCKED position. machine.
3. Turn the engine start switch to the ON position.
4. Move the joysticks and the travel levers/pedals

to the full stroke positions in order to relieve the
pressure in the pilot lines.
5. Turn the engine start switch to the OFF position

and return the lever for the hydraulic lockout
control to the LOCKED position.
g00687481
Illustration 386
The case drain filter is located near the pilot oil filter.
9. Clean the area around the filter in order to keep

dirt out of the filter mounting base.
10. Remove the used case drain filter from the filter
mounting base.
Note: This element is a cartridge type filter. The

g00687449
Illustration 384 element cannot be reused.
6. Slowly loosen the fill/vent plug on top of the Note: Used filters should always be disposed of
hydraulic tank in order to relieve the internal according to local regulations.
pressure of the hydraulic tank.
7. After the pressure is relieved, tighten the fill/vent of the old filter seal is removed.
plug.
192 SEBU7342-08
Maintenance Section
g00101502 g00687286
(A) High temperature range
12. Apply clean hydraulic oil to the seal of the new (B) Low temperature range
case drain filter.
18. Maintain the oil level in the low temperature range
13. Install the new filter hand tight until the seal of the for a cold machine. Maintain the oil level in the
filter contacts the filter mounting base. Note the high temperature range for a machine that is at a
position of the index marks on the filter in relation normal operating temperature.
to a fixed point on the filter mounting base.
Note: There are rotation index marks on the filter

that are spaced 90 degrees or 1/4 of a turn away
from each other. When you tighten the filter, use the
rotation index marks as a guide.
14. Tighten the filter according to the instructions that

are printed on the filter. Use the index marks as a
guide for tightening the filter.

wrench, or another suitable tool, in order to turn
g00687449
not damage the filter. Illustration 389
15. Start the engine and operate the machine slowly 19. Slowly loosen the fill/vent plug in order to relieve
for 10 to 15 minutes. Move each cylinder evenly any pressure. Remove the fill/vent plug in order
through several cycles. to add oil, if necessary.
16. Return the machine to the position that is shown 20. Clean the fill/vent plug. Install the fill/vent plug.
in Illustration 382. Check the machine for oil leaks.
17. Stop the engine.
SEBU7342-08 193
Maintenance Section
Hydraulic System Oil Filter (Pilot) - Replace
i02232803

(Pilot) - Replace
SMCS Code: 5068-510; 5068-510-PS; 5092-510
g00687449
Illustration 392
6. Slowly loosen the fill/vent plug on top of the

hydraulic tank in order to relieve the internal
pressure of the hydraulic tank.
Illustration 390
g00101435 7. After the pressure is relieved, tighten the fill/vent
plug.
g00101497
Illustration 393
Illustration 391
g00811329 8. Open the access door on the right side of the
machine.
2. Move the lever for the hydraulic lockout control to
the UNLOCKED position.
3. Turn the engine start switch to the ON position.
4. Move the joysticks and the travel levers/pedals

to the full stroke positions in order to relieve the
pressure in the pilot lines.
5. Turn the engine start switch to the OFF position

and return the lever for the hydraulic lockout
control to the LOCKED position.
g00687480
Illustration 394
9. Clean the area around the filter in order to keep

dirt out of the filter base.
194 SEBU7342-08
Maintenance Section
Hydraulic System Oil Filter (Return) - Replace
10. Remove the used pilot filter element from the filter
mounting base.
Note: This element is a cartridge type filter. The

element cannot be reused.
Note: Used filters should always be disposed of

of the old filter seal is removed.
g00687286
Illustration 396
(A) High temperature range
(B) Low temperature range
18. Maintain the oil level in the low temperature range

for a cold machine. Maintain the oil level in the
high temperature range for a machine that is at a
normal operating temperature.
g00101502
Illustration 395
12. Apply clean hydraulic oil to the seal of the new

pilot filter.
13. Install the new filter hand tight until the seal of the
filter contacts the filter mounting base. Note the
position of the index marks on the filter in relation
to a fixed point on the filter mounting base.
Note: There are rotation index marks on the filter

that are spaced 90 degrees or 1/4 of a turn away
g00687449
from each other. When you tighten the filter, use the Illustration 397
rotation index marks as a guide.
19. Slowly loosen the fill/vent plug in order to relieve
14. Tighten the filter according to the instructions that any pressure. Remove the fill/vent plug in order
are printed on the filter. Use the index marks as a to add oil, if necessary.
guide for tightening the filter.
20. Clean the fill/vent plug. Install the fill/vent plug.
wrench, or another suitable tool, in order to turn 21. Close the access door.
i01835391
not damage the filter.
15. Start the engine and operate the machine slowly
for 10 to 15 minutes. Move each cylinder evenly (Return) - Replace
through several cycles.
SMCS Code: 5068-510-RJ
16. Return the machine to the position that is shown
in Illustration 390. Check the machine for oil leaks. The return filter is a cartridge type filter. The amount
of foreign material that enters the hydraulic system is
17. Stop the engine. reduced when the filter element is replaced.
SEBU7342-08 195
Maintenance Section
Two different filters are available for the return filter. a. Remove bolts (1), washers (2), and cover (3).
One filter is used for standard applications such as
digging and normal use of a hammer. The second Note: Refer to Operation and Maintenance Manual,
filter is used for an application such as demolishing a General Hazard Information for information on
ceiling in a tunnel with a hammer. containing fluid spillage.
Note: If the message display shows that the hydraulic b. Remove plug (4) in order to release the
return filter is plugged, turn off the machine. After you pressure in filter cartridge (5).
make sure that the warning has disappeared, start
the machine and run the machine on level ground for Note: When plug (4) is removed the oil level in the
approximately 10 minutes. If the warning still appears return filter drops to the level of the hydraulic tank.
in the message display, inspect the filter and replace
the filter, if necessary.
g00102212
Illustration 400
(5) Filter cartridge
g00687518
Illustration 398 (6) Filter case
(A) Guide
1. Loosen the fill/vent plug in order to relieve the
hydraulic tank pressure. Tighten the fill/vent plug c. Pull up the handle at the top of filter cartridge
after the hydraulic tank pressure is relieved. (5) until the filter cartridge contacts guide (A)
on filter case (6).
Note: The return filter cartridge is located behind the
fill/vent plug.
2. Remove the filter cartridge. Perform Step 2.a

through Step 2.f in order to remove the filter
cartridge.
g00102214
Illustration 401
d. Turn the filter cartridge counterclockwise by

180 degrees in order to align the projection of
the filter cartridge with the notch of the filter
case. Pull out the filter cartridge.
g00102211
Illustration 399
(1) Bolts
(2) Washers
(3) Cover
(4) Plug
(5) Filter cartridge
196 SEBU7342-08
Maintenance Section
g00102219 g00918893
(7) O-ring (8) Plate
(9) Spiral retaining ring
e. Inspect the cover and O-ring (7). If either part
is damaged, replace the part. b. Remove spiral retaining ring (9).
f. Inspect the filter cartridge for debris and

for damage. If necessary, replace the filter
cartridge.
3. Remove the filter element. Perform Step 3.a

through Step 3.f in order to remove the filter
element.
g00104510
Illustration 405
(8) Plate
(10) Shell
(11) O-ring
(12) Filter element
c. Hold the filter cartridge with one hand. Grasp

the grip of plate (8) with your other hand. Lift
Illustration 403
g00104507 plate (8) in order to separate plate (8) from the
filter cartridge.
(4) Plug
(8) Plate
(18) O-ring d. Remove O-ring (11) from plate (8).
a. Make sure that plug (4) is removed. Make sure e. Lift filter element (12) from shell (10).
that all of O-ring (18) is removed from plate (8).
f. Pour the remaining oil into a suitable container.
Note: Dispose of used oil according to local

regulations.
g. Repeat Step 3.a through Step 3.f for the other

filter groups.
4. Clean the shell of the filter cartridge. Perform Step

4.a through Step 4.d in order to clean the shell of
the filter cartridge.
SEBU7342-08 197
Maintenance Section
g00104511 g00104512
(13) Slide plate (8) Plate
(14) Pads (10) Shell
(15) Screws (16) Boss
(19) Port (17) Notch
a. Turn shell (10) upside-down. g. Turn over shell (10). Apply grease to the two
O-rings on new element (12). Install element
b. Remove screws (15). (12) into shell (10).
c. Remove Pads (14) from slide plate (13). h. Move boss (16) in alignment with notch (17).
Install plate (8) into shell (10).
d. Wash the following parts in a clean
nonflammable solvent: plug (4), plate (8), spiral i. Install spiral retaining ring (9) into the groove
retaining ring (9), shell (10), and Pads (14). Dry in shell (10).
the parts.
j. Apply grease to new O-ring (18). Install O-ring
5. Install the filter elements. Perform Step 5.a through (18) on plug (4).
Step 5.k in order to install the filter elements.
k. Install plug (4) into plate (8).
Note: Consult a Caterpillar dealer for the Service Kit
that is needed to install the filter element and the 6. Install the filter cartridge. Perform Step 6.a through
filter cartridge. Step 6.e in order to install the filter cartridge.
a. Apply spray type oil to the inside of shell (10) in

order to prevent rust.
b. Apply grease to a new O-ring (11).
c. Plate (8) will contact the inside of shell (10).

Apply grease to this point.
d. Apply grease to O-rings inside ports (19) at the

bottom of shell (10).
e. Install new Pads (14). Tighten the screws to a

torque of 0.4 Nm (3.5 lb in).
g00102220
f. Apply spray type oil into the clearance between Illustration 408
shell (10) and slide plate (13). (B) Port
(C) Slide plate
a. Check that ports (B) at the bottom of the filter

case are closed.
198 SEBU7342-08
Maintenance Section
Hydraulic System Oil Level - Check
Note: If the ports are open, rotate slide plate (C)

counterclockwise to the stopper in order to fully
close the ports. When the ports are fully closed, any
remaining oil in the filter case should be completely
removed.
g00102225
Illustration 411
(1) Bolts
d. Install the filter cartridge into the filter case.

Turn the filter cartridge clockwise by 180
g00102221
Illustration 409 degrees and push down the filter cartridge
(E) Slide plate when the filter cartridge contacts guide (A).
(D) Port
e. Install plug (4), cover (3), washers (2), and bolts
b. Check that ports (D) of the filter cartridge are (1). Tighten bolts (1) to a torque of 29 5 Nm
fully closed. (22 4 lb ft).
Note: The filter cartridge cannot be installed unless

the ports are fully closed. If the ports are open, rotate i01297741
slide plate (E) counterclockwise to the stopper in
order to fully close the ports.
Hydraulic System Oil Level -
Check
SMCS Code: 5050-535
NOTICE
Never remove the fill/vent plug from the hydraulic tank
if the oil is hot.
Air can enter the system and cause pump damage.
g00102222
Illustration 410
(F) O-rings
c. Check that O-rings (F) have been installed and

that oil has been applied to O-rings (F).
g00102817
Illustration 412
The hydraulic oil tank is on the right side of the machine.

bucket to the ground with the stick in a vertical
position, as shown.
SEBU7342-08 199
Maintenance Section
Hydraulic System Oil Sample - Obtain
Note: Perform Step 5 through Step 7 if the oil level

is low.
5. Slowly loosen the fill/vent plug in order to relieve

any pressure. Add oil, if necessary.
6. Check the O-ring seal of the fill/vent plug. Replace

the O-ring seal if the O-ring seal is damaged.
7. Clean the fill/vent plug and install the fill/vent plug.
i01874371
Hydraulic System Oil Sample

Illustration 413
g00102818
- Obtain
2. Open the access door on the right side of the SMCS Code: 5050-008-OC; 5095-008; 5095-SM;
machine. 7542-008; 7542
g00687286
g00684914
3. For a cold machine, maintain the hydraulic oil level The hydraulic oil sampling valve is near the pilot filter.
in the low temperature range. For a machine that Obtain a sample of the hydraulic oil from the hydraulic
is at normal operating temperature, maintain the oil sampling valve that is located on the hydraulic
hydraulic oil level in the high temperature range. oil filter housing. Refer to Special Publication,
SEBU6250, SOS Oil Analysis for information that
4. Close the access door. pertains to obtaining a sample of the hydraulic oil.
Refer to Special Publication, PEHP6001, How To
Take A Good Oil Sample for more information about
obtaining a sample of the hydraulic oil.
g00687449
Illustration 415

General Hazard Information for information that
pertains to Containing Fluid Spillage.
200 SEBU7342-08
Maintenance Section
Hydraulic Tank Screen - Clean
i01305086
Hydraulic Tank Screen - Clean

SMCS Code: 5056-070-Z3
g00687312
Illustration 419
3. Clean the area thoroughly in order to keep dirt out

of the screen cover. Clean the area thoroughly in
g00101435
order to keep dirt out of the fill/vent plug.
Illustration 417
4. Relieve the internal pressure from the hydraulic
1. Park the machine on level ground. Lower the tank by loosening the fill/vent plug. After the
bucket to the ground so that the stick is vertical. pressure is relieved, remove the fill/vent plug.
g00687272 g00691202
(1) Bolts (4) Bolts
(2) Washers (5) Washers
(3) Cover (6) Cover
(7) Spring
2. Remove bolts (1), washers (2) and cover (3) from (8) Screen
the top of the hydraulic tank.
5. Remove bolts (4), washers (5) and cover (6).
Note: Do not allow spring (7) to fall into the tank.
6. Remove spring (7) and screen (8).
Note: Refer to Operation and Maintenance, General

Hazard Information for information on containing
fluid spillage.
SEBU7342-08 201
Maintenance Section
Indicators and Gauges - Test
7. Wash the screen in a clean nonflammable solvent. i01297835

Allow the screen to dry. Inspect the screen.
Replace the screen, if the screen is damaged. Indicators and Gauges - Test
SMCS Code: 7450-081; 7490-081
g00691204
Illustration 421
(9) O-ring seal g00687578
(10) O-ring seal Illustration 422
8. Remove O-ring seal (9) from screen (12). 1. Look for broken lenses on the gauges, broken
indicator lights, broken switches, and other broken
9. Inspect O-ring seals (9) and (10). Replace the components in the cab.
O-ring seals if wear or damage is evident.
2. Start the engine.
10. Install O-ring seal (9) on screen (12).
3. Look for inoperative gauges.
11. Install screen (8) and spring (7). Then install cover
(6), washers (5), and bolts (4). 4. Turn on all machine lights. Check for proper
operation.
Note: Make sure that the O-ring seals and the spring
are properly positioned during installation. 5. Move the machine forward. Release the travel
levers and the travel pedals. The machine should
12. Inspect the O-ring seal on the filler plug for stop.
damage. Replace the O-ring, if necessary. Clean
the filler plug. Install the filler plug. 6. Stop the engine.
13. Install cover (3) with bolts (1) and washers (2). 7. Make any repairs that are required before
operating the machine.
202 SEBU7342-08
Maintenance Section
Oil Filter - Inspect
i02106227 i01281217
Oil Filter - Inspect Radiator Core - Clean

SMCS Code: 1308-507; 5068-507 SMCS Code: 1353-070
S/N: ANB1-Up
Inspect a Used Filter for Debris
S/N: AMC1-Up
S/N: BDC1-Up
S/N: CCD1-Up
S/N: BER1-Up
Machines without a Swing Out

Hydraulic Oil Cooler
1. Raise the engine hood and open the access door
on the left side of the machine.
g00100013
Illustration 423
The element is shown with debris.
Use a filter cutter to cut the filter element open.

Spread apart the pleats and inspect the element for
metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
failure.
If metals are found in the filter element, a magnet can

be used to differentiate between ferrous metals and
nonferrous metals.
g00679158
Ferrous metals can indicate wear on steel parts and Illustration 424
on cast iron parts. (1) Wing bolts
(2) Screen
Nonferrous metals can indicate wear on the
aluminum parts of the engine such as main bearings, 2. Loosen wing bolts (1) and remove screens (2)
rod bearings, or turbocharger bearings. from the radiator.
Small amounts of debris may be found in the filter

element. This could be caused by friction and by
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount
of debris is found.
Using an oil filter element that is not recommended

by Caterpillar can result in severe engine damage
to engine bearings, to the crankshaft, and to other
parts. This can result in larger particles in unfiltered
oil. The particles could enter the lubricating system
and the particles could cause damage.
g00679159
Illustration 425
3. Check the radiator fins for debris.

SEBU7342-08 203
Maintenance Section
Radiator Core - Clean
g00424879 g00679162
(3) Latch
4. Remove dust and debris from the radiator fins and
from screen (2). 3. Raise latch (3) and rotate the latch by 1/2 turn.
Compressed air is preferred, but high pressure

water or steam can be used to remove dust and
general debris from a radiator. Clean the radiator
according to the condition of the radiator.
See Special Publication, SEBD0518, Know Your

Cooling System for more detailed information
about cleaning radiator fins.
5. Install screens (2) with wing bolts (1).
6. Close the engine hood and close the access door.
Machines with a Swing Out g00679164

Illustration 429
Hydraulic Oil Cooler (3) Latch
(4) Hydraulic oil cooler
1. Raise the engine hood and open the access door (5) Radiator
on the left side of the machine.
4. Swing hydraulic oil cooler (4) outward.
5. Check for accumulated dust in the fins of hydraulic

oil cooler (4) and radiator (5).
6. Clean the fins of the hydraulic oil cooler and the

radiator with compressed air, pressurized water
or steam.
g00679158
Illustration 427
(1) Wing bolts
(2) Screen
2. Loosen wing bolts (1) and remove screens (2)

from the radiator.
204 SEBU7342-08
Maintenance Section
Radiator, Aftercooler and Oil Cooler Cores - Clean
g00424879 g00937671
(1) Engine hood
7. Remove dust and debris from the radiator fins and (2) Access door
from screens (2). (3) Wing bolts
(4) Screen
water or steam can be used to remove dust and 2. Loosen wing bolts (3) and remove screens (4)
general debris from a radiator. Clean the radiator from the radiator.
according to the condition of the radiator.
See Special Publication, SEBD0518, Know Your

8. After cleaning, swing in hydraulic oil cooler (4)

and secure latch (3).
9. Install screens (2) with wing bolts (1).
10. Close the engine hood and close the access door.
i01835392
g00937672
Illustration 432
Radiator, Aftercooler and Oil
3. Check the fins for debris.
Cooler Cores - Clean
SMCS Code: 1063-070-KO; 1353-070-KO;
1374-070-KO
S/N: MAB1-Up
S/N: PAB1-Up
S/N: SBN1-Up
S/N: RAW1-Up
1. Raise the engine hood (1) and open the access

door (2) on the left side of the machine.
g00424879
Illustration 433
4. Remove dust and debris from the fins and from

screen (4).
SEBU7342-08 205
Maintenance Section
Receiver Dryer (Refrigerant) - Replace

water or steam can be used to remove dust and NOTICE
general debris from the fins and screens. Clean If the refrigerant system has been open to the outside
the radiator according to the condition of the air (without being plugged) for more than 30 minutes,
radiator. the receiver-dryer must be replaced. Moisture will en-
ter an open refrigerant system and cause corrosion
See Special Publication, SEBD0518, Know Your which will lead to component failure.
Refer to Service Manual, SENR5664, Air
5. Install screens (4) with wing bolts (3). Conditioning and Heating System with R-134a
Refrigerant for All Caterpillar Machines for the proper
6. Close the engine hood (1)and close the access procedure to change the receiver-dryer assembly
door (2). and for the procedure to reclaim the refrigerant gas.
i02723802 i02429589
Receiver Dryer (Refrigerant) - Seat Belt - Inspect

Replace SMCS Code: 7327-040
SMCS Code: 7322-510; 7322-710 Always check the condition of the seat belt and the
condition of the seat belt mounting hardware before
you operate the machine. Replace any parts that are
damaged or worn before you operate the machine.
Personal injury can result from contact with refrig-
erant.
Contact with refrigerant can cause frost bite. Keep

face and hands away to help prevent injury.
Protective goggles must always be worn when re-

frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant.
Always use precaution when a fitting is removed.

Slowly loosen the fitting. If the system is still un-
der pressure, release it slowly in a well ventilated
area.
g00932801
Illustration 434
Personal injury or death can result from inhaling
refrigerant through a lit cigarette. Typical example
Inhaling air conditioner refrigerant gas through a Check the seat belt mounting hardware (1) for wear
lit cigarette or other smoking method or inhaling or for damage. Replace any mounting hardware that
fumes released from a flame contacting air con- is worn or damaged. Make sure that the mounting
ditioner refrigerant gas, can cause bodily harm or bolts are tight.
death.
Check buckle (2) for wear or for damage. If the buckle
Do not smoke when servicing air conditioners or is worn or damaged, replace the seat belt.
wherever refrigerant gas may be present.
Inspect the seat belt (3) for webbing that is worn or
Use a certified recovery and recycling cart to prop- frayed. Replace the seat belt if the seat belt is worn
erly remove the refrigerant from the air condition- or frayed.
ing system.
Consult your Caterpillar dealer for the replacement of
the seat belt and the mounting hardware.
206 SEBU7342-08
Maintenance Section
Seat Belt - Replace
Note: Within three years of the date of installation or Note: Do not overgrease the swing bearings. Do not
within five years of the date of manufacture, replace grease more than the recommended maintenance
the seat belt. Replace the seat belt at the date which interval. Refer to Operation and Maintenance
occurs first. A date label for determining the age of Manual, Maintenance Interval Schedule for more
the seat belt is attached to the seat belt, the seat belt information.
buckle, and the seat belt retractor.
Wipe the fittings before you lubricate the swing
If your machine is equipped with a seat belt bearing.
extension, also perform this inspection procedure for
the seat belt extension.
i02429594
Seat Belt - Replace

SMCS Code: 7327-510
Within three years of the date of installation or within

five years of the date of manufacture, replace the
seat belt . Replace the seat belt at the date which
occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor. g00101569
Illustration 436
The swing bearing is located under the base of the

boom.
g01152685
Illustration 435
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Date of manufacture (tag) (fully extended web)
(4) Date of manufacture (underside) (buckle)
g00687903
Illustration 437
Consult your Caterpillar dealer for the replacement of
the seat belt and the mounting hardware. Apply lubricant through the fittings until the lubricant
overflows the bearing seals.
If your machine is equipped with a seat belt
extension, also perform this replacement procedure
for the seat belt extension. i02582097
Swing Drive Oil - Change

i02378698
SMCS Code: 5459-044
Swing Bearing - Lubricate
SMCS Code: 7063-086
Note: Refer to Special Publication, SEBU6250, Hot oil and hot components can cause personal
Caterpillar Machine Fluids Recommendations for injury. Do not allow hot oil or hot components to
more information on grease. contact skin.
SEBU7342-08 207
Maintenance Section
Swing Drive Oil - Change
g00101586 g00687982
The oil drain hose is under the center of the upper 3. Tighten the drain valve. Hook the drain hose (2)
structure. to the holder (1). Make sure that the end of the
hose is facing upward.
g00687981
Illustration 439
g00687983
Illustration 441
General Hazard Information for information that 4. Remove dipstick (4).
5. Add the specified quantity of oil through the
1. Remove drain hose (2) from holder (1) on the dipstick tube. See Operation and Maintenance,
upper frame. Face the end of the hose toward Capacities (Refill).
the container.
6. Check the oil level. Refer to Operation and
2. Use a universal joint with a socket extension to Maintenance Manual, Swing Drive Oil Level -
loosen the drain valve in hole (3). Drain the oil into Check for the procedure.
a suitable container.
7. Check the oil that has been drained for metal chips
Note: Drained fluids should always be disposed of or metal particles. Consult your Caterpillar dealer
according to local regulations. if any metal chips or metal particles are found.
8. Drained materials should always be disposed of

208 SEBU7342-08
Maintenance Section
Swing Drive Oil Level - Check
i02582101
Swing Drive Oil Level - Check

SMCS Code: 5459-535-FLV

injury. Do not allow hot oil or hot components to
contact skin.
g01049757
Illustration 444

General Hazard Information for information that
2. Check the dipstick. Maintain the oil level between

the marks on the dipstick. Add oil through the
dipstick tube, if necessary. Refer to Operation
and Maintenance Manual, Lubricant Viscosities
when you select an oil. If the oil level is above
g00101622
the FULL line, then remove oil from the system.
Illustration 442 Restore the oil to the correct level position.
The dipstick for the swing drive oil is on the swing 3. Insert the dipstick.
drive at the rear base of the boom.
i02582981
Swing Drive Oil Sample -

Obtain
SMCS Code: 5459-008; 5459-008-OC;
5459-554-OC; 5459-OC; 7542-008

injury. Do not allow hot oil or hot components to
contact skin.
g00684917
Illustration 443
1. Remove the dipstick.
g00684917
Illustration 445
SEBU7342-08 209
Maintenance Section
Swing Gear - Lubricate
Obtain an oil sample of the swing drive oil through the

opening for the dipstick. Refer to Special Publication,
SEBU6250, SOS Oil Analysis for information
that pertains to obtaining an oil sample from the
swing drive housing. Refer to Special Publication,
PEHP6001, How To Take A Good Oil Sample for
more information about obtaining an oil sample from
the swing drive housing.
i01963879
Swing Gear - Lubricate

SMCS Code: 7063-086
g00688056
Illustration 447
Note: Refer to Special Publication, SEBU6250,
(1) Bolts
Caterpillar Machine Fluids Recommendations for (2) Washers
more information on grease. (3) Cover
(4) Gasket
NOTICE
1. Remove bolts (1) and washers (2). Remove cover
Improper lubrication can cause damage to machine
(3) and gasket (4).
components.
To avoid damage, make sure that the proper amount

of grease is applied to the swing drive.
When the amount of grease in the compartment be-

comes too large, the agitation loss becomes large,
thereby accelerating grease deterioration.
Grease deterioration can cause damage to the pinion

gear of the swing drive and swing internal gear.
Not enough grease will result in poor gear lubrication.
g00688058
Illustration 448
(3) Cover
(4) Gasket
2. Inspect gasket (4). Replace the gasket if damage

is evident.
3. Check the level of the grease. The grease should

be evenly distributed on the floor of the pan.
Refer to Operation and Maintenance Manual,

Capacities (Refill) for the size of the pan.
g00688052
Illustration 446 Add grease, as needed. Remove grease, as
needed. Too much grease will result in the
Remove the inspection cover that is located near the deterioration of the grease because of excessive
boom base. Inspect the grease. movement of the grease. Too little grease will
result in poor lubrication of the swing gear.
210 SEBU7342-08
Maintenance Section
Track Adjustment - Adjust
i02909086

SMCS Code: 4170-025
Personal injury or death can result from grease

under pressure.
Grease coming out of the relief valve under pres-

sure can penetrate the body causing injury or
death.
g00688063
Illustration 449
Do not watch the relief valve to see if grease is es-
(5) Bolts caping. Watch the track or track adjustment cylin-
(6) Washers
(7) Cover
der to see if the track is being loosened.
(8) Gasket
Loosen the relief valve one turn only.
4. Check for contamination and for discolored
grease. If track does not loosen, close the relief valve and
contact your Caterpillar dealer.
5. If the grease is contaminated or discolored with
water, change the grease. Remove bolts (5),
washers (6), cover (7), and gasket (8) in order NOTICE
to allow the water to drain. When you reinstall Keeping the track properly adjusted will increase the
cover (7), inspect gasket (8). Replace the gasket service life of the track and drive components.
if damage is evident.
Note: The track tension must be adjusted according
to the current operating conditions. Keep the track as
slack as possible if the soil is heavy.
Measuring Track Tension

1. Operate the machine in the direction of the idlers.
g00101644
Illustration 450
6. Raise the boom and turn the upper structure by

1/4 turn. Lower the bucket to the ground.
7. Repeat Step 6 at every 1/4 turn in four places.

Add grease, as needed.
g01103855
Illustration 451
8. Install gasket (4), cover (3), washers (2), and bolts
(1).
2. Stop with one track pin directly over the front
carrier roller. Park the machine and turn off the
engine.
SEBU7342-08 211
Maintenance Section
Tightening the Track
g00101752
Illustration 452
g01091134
Illustration 454
3. Place a straight edge on top of the track grousers
(1) Grease fitting
between the front carrier roller and the idler. The (2) Relief valve
straight edge should be long enough to reach from
the front carrier roller to the idler. Wipe the fitting before you add grease.
4. Measure the maximum amount of sag in the track. 1. Add grease through grease fitting (1) until the
The sag is measured from the highest point of the correct track tension is reached.
track grouser to the bottom of the straight edge. A
track that is properly adjusted will have a sag of 2. Operate the machine back and forth in order to
40.0 to 55.0 mm (1.57 to 2.17 inch). equalize the pressure.
5. If the track is too tight, or if the track is too 3. Check the amount of sag. Adjust the track, as
loose, adjust the track tension according to the needed.
appropriate procedure below.
Loosening the Track
Adjusting Track Tension
g01091134
Illustration 455
g00270405
Illustration 453 (1) Grease fitting
Typical example (2) Relief valve
The track adjuster is located on the track frame. 1. Loosen relief valve (2) carefully until the track
begins to loosen. One turn should be the
maximum.
2. Tighten relief valve (2) to 34 5 Nm (25 4 lb ft)

when the desired track tension is reached.
3. Operate the machine back and forth in order to

equalize the pressure.
212 SEBU7342-08
Maintenance Section
Track Adjustment - Inspect
4. Check the amount of sag. Adjust the track, as

needed.
i01590290
Track Adjustment - Inspect

SMCS Code: 4170-040
g00560313
Illustration 457
3. Use the travel levers or the travel pedals to move

the machine forward. The travel alarm should
sound.
4. Release the travel levers and the travel pedals in

order to stop the machine.
g00824541
Illustration 456
5. Use the travel levers and the travel pedals to
Check the track adjustment. Check the track for wear move the machine backward. The travel alarm
and for excessive dirt buildup. should sound.
If the track appears to be too tight or too loose,

refer to Operation and Maintenance Manual, Track
Adjustment - Adjust.
i02252128
Travel Alarm - Test

(If Equipped)
SMCS Code: 7429-081
You must move the machine in order to test the travel

alarm. Illustration 458
g00688104
1. Start the engine. Move the hydraulic lockout 6. Push the alarm cancel switch. The travel alarm
control to the UNLOCKED position. should shut off.
2. Raise the work tools in order to avoid any 7. Stop the machine. Lower the work tools. Move the
obstacles. Make sure that there is adequate Hydraulic lockout control to the LOCKED position.
overhead clearance. Stop the engine.
SEBU7342-08 213
Maintenance Section
Undercarriage - Check
i00059532
Undercarriage - Check
SMCS Code: 4150-535
g00101429
Illustration 460
1. Open the rear access door on the left side of the

machine.
g00101898
Illustration 459
1. Check the carrier rollers, the track rollers, and the

idler wheels for possible leakage.
2. Check the surface of the track, the carrier rollers,

the track rollers, the idler wheels, the track shoes,
and the drive sprockets. Look for signs of wear
and loose mounting bolts.
3. Listen for any abnormal noises while you are

moving slowly in an open area.
4. If abnormal wear exists or abnormal noises or

g00688996
leaks are found, consult your Caterpillar dealer. Illustration 461
2. Remove the filler cap.

i01300116
Window Washer Reservoir - 3. Fill the window washer reservoir with washer fluid
through the filler opening.
Fill
4. Install the filler cap.
SMCS Code: 7306-544-KE
NOTICE
When operating in freezing temperatures, use i01258249
Caterpillar or any commercially available nonfreezing
window washer solvent. Window Wiper -
Inspect/Replace
SMCS Code: 7305-040; 7305-510
Inspect the condition of the wiper blades. Replace

the wiper blades if the wiper blades are worn or
damaged or if streaking occurs.
214 SEBU7342-08
Maintenance Section
Windows - Clean
i01077829
Windows - Clean
SMCS Code: 7310-070; 7340-070
Use commercially available window cleaning

solutions in order to clean the windows. Clean the
outside of the windows from the ground, unless
handholds are available.
g00566124
Illustration 462
Typical example
Use a pole with a squeegee in order to reach the high

areas of the window.
Cleaning Methods
Aircraft Windshield Cleaner
Apply the cleaner with a soft cloth. Rub the window
with moderate pressure until all the dirt is removed.
Allow the cleaner to dry. Wipe off the cleaner with a
clean soft cloth.
Soap and Water

Use a clean sponge or a soft cloth. Wash the windows
with a mild soap or with a mild detergent. Also
use plenty of lukewarm water. Rinse the windows
thoroughly. Dry the windows with a moist chamois or
with a moist cellulose sponge.
Stubborn Dirt and Grease

Wash the windows with a good grade of naphtha, of
isopropyl alcohol, or of Butyl Cellosolve. Then, wash
the windows with soap and with water.

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MAINTENANCE INTERVALS

Operation and Maintenance

i03023880 Window Wiper - Inspect/Replace ........................ 213

Every 250 Service Hours of Continuous Every Year

Engine Crankcase Breather - Clean ................... 174

Every 500 Service Hours of Partial Hammer

Every 600 Service Hours of Continuous

Every 1000 Service Hours or 6 Months

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the following

Battery Hold-Down - Tighten

Tighten the hold-downs for the battery in order to

The recirculation filter is on the lower left side of the

1. To remove the filter element, slide the element

2. Refer to Operation and Maintenance Manual,

3. Clean the filter element with a maximum of

Battery or Battery Cable - Belts - Inspect/Adjust/Replace

Batteries give off flammable fumes that can ex-

Prevent sparks near the batteries. Sparks could

Always wear protective glasses when working

2. Turn the battery disconnect switch to the OFF

3. Disconnect the negative battery cable at the

4. Disconnect the positive battery cable at the

5. Disconnect the battery cables at the battery

6. Make necessary repairs or replace the battery.

7. Connect the battery cable at the battery disconnect

8. Connect the positive battery cable of the battery.

9. Connect the negative battery cable of the battery. g00937676

Your engine is equipped with a water pump, with

If new belts are installed, recheck the belt adjustment

3. Measure the deflection of the belt. The belt should

4. If the deflection is not correct, loosen alternator

5. When the adjustment is correct, tighten bolt (1)

6. Check the deflection of the belt again.

Air Conditioner Belt (If Equipped)

2. Measure the deflection of the belt. The belt should

Boom Cylinder Head (Long

Note: Caterpillar recommends the use of 5%

Wipe all fittings before you apply lubricant.

Apply lubricant through all fittings after operation

Wipe all fittings before you apply lubricant.

5. Apply lubricant through fitting (6). Fitting (6) is at

Unexpected machine movement can cause injury

Note: To ensure proper lubrication of the lower boom

6. Apply lubricant through fitting (12) for the head

Two shims of different thickness are used at location

Wipe all fittings before you apply lubricant.

1. Position the machine on a level surface and lower

2. Slowly operate the swing control lever until stick

Subtract 0.5 mm (0.02 inch ) or 1.0 mm (0.04 inch)

6. Remove the appropriate number of shims at

7. After the correct number of shims has been

Bucket Tips - Inspect/Replace

Block the bucket before changing the bucket

To prevent possible injury to the eyes, wear a pro-

Bucket Tips a. Place the Pin-Master on the bucket tip.

b. Align extractor (5) with the pin.

c. Strike the Pin-Master at the back of the tool (4)

Note: Discard the old pin and the retainer assembly.

Use a Pin-Master. Follow Step 5.a through Step

e. Strike the end of the tool until the pin is fully

a. Insert pin (8) through the bucket tip.

Note: Some side cutters may be rotated for additional