320D Excavator-Maintenance Intervals

SAFETY.CAT.
COM
320D
EXCAVATOR
Maintenance Intervals
Excerpted from Operation & Maintenance Manual (SEBU8371-00-01)
© 2007 Caterpillar
All Rights Reserved
SEBU8371 143
Maintenance Section
Maintenance Interval Schedule
i02768213 Every 10 Service Hours or Daily

Maintenance Interval Schedule Cooling System Coolant Level - Check .............. 160
Engine Oil Level - Check .................................... 166
SMCS Code: 7000 Fuel System Water Separator - Drain ................. 174
Fuel Tank Water and Sediment - Drain ............... 175
Ensure that all safety information, warnings, Hydraulic System Oil Level - Check ................... 189
and instructions are read and understood before Indicators and Gauges - Test .............................. 192
any operation or any maintenance procedures Seat Belt - Inspect .............................................. 194
are performed. The user is responsible for Track Adjustment - Inspect ................................. 201
the performance of maintenance, including all Travel Alarm - Test .............................................. 201
adjustments, the use of proper lubricants, fluids, Undercarriage - Check ........................................ 202
filters, and the installation of new components
due to normal wear and aging. The performance Every 10 Service Hours or Daily for Machines
of this product may be diminished if proper Used in Severe Applications
maintenance intervals and procedures are not
followed. Components may experience accelerated Bucket Linkage - Lubricate ................................. 149
wear if proper maintenance intervals and procedures
are not followed. Every 50 Service Hours or Weekly
Use fuel consumption, service hours, or calendar Quick Coupler - Lubricate ................................... 193
time, WHICH EVER OCCURS FIRST, in order to
determine the maintenance intervals. Products that Every 100 Service Hours or 2 Weeks
operate in severe operating conditions may require
Bucket Linkage - Lubricate ................................. 149
more frequent maintenance.
Before each consecutive interval is performed, all Every 100 Service Hours or 2 Weeks for
maintenance from the previous intervals must be Machines Used in Severe Applications
performed.
Boom and Stick Linkage - Lubricate ................... 147
When Required Initial 250 Service Hours
Air Conditioner/Cab Heater Filter (Recirculation) -
Engine Valve Lash - Check ................................. 169
Inspect/Replace ................................................ 145
Final Drive Oil - Change ..................................... 169
Battery - Recycle ................................................ 145 Hydraulic System Oil Filter (Case Drain) -
Battery or Battery Cable - Inspect/Replace ........ 145
Replace ............................................................. 182
Bucket Linkage - Inspect/Adjust ......................... 148
Hydraulic System Oil Filter (Pilot) - Replace ....... 184
Bucket Tips - Inspect/Replace ............................ 149 Hydraulic System Oil Filter (Return) - Replace ... 185
Bucket Tips - Inspect/Replace ............................ 153
Swing Drive Oil - Change ................................... 195
Cab Air Filter (Fresh Air) - Clean/Replace .......... 156
Circuit Breakers - Reset ...................................... 156
Engine Air Filter Primary Element - Clean/ Every 250 Service Hours
Replace ............................................................. 162 Cooling System Coolant Sample (Level 1) -
Engine Air Filter Secondary Element - Replace .. 165 Obtain ............................................................... 161
Fuel System - Prime ........................................... 171 Engine Oil Sample - Obtain ................................ 167
Fuses - Replace .................................................. 175 Final Drive Oil Sample - Obtain .......................... 170
High Intensity Discharge Lamp (HID) - Replace .. 177
Oil Filter - Inspect ................................................ 192 Every 250 Service Hours or Monthly
Radiator Core - Clean ......................................... 193
Receiver Dryer (Refrigerant) - Replace .............. 194 Belt - Inspect/Adjust/Replace .............................. 146
Track Adjustment - Adjust ................................... 199 Condenser (Refrigerant) - Clean ........................ 157
Window Washer Reservoir - Fill .......................... 202 Final Drive Oil Level - Check .............................. 170
Window Wiper - Inspect/Replace ........................ 202 Swing Bearing - Lubricate ................................... 195
Windows - Clean ................................................. 202 Swing Drive Oil Level - Check ............................ 197
Every 10 Service Hours or Daily for First 100 Every 250 Service Hours of Partial Hammer
Hours Use (50% of Service Hours)
Boom and Stick Linkage - Lubricate ................... 147 Hydraulic System Oil Filter (Case Drain) -
Bucket Linkage - Lubricate ................................. 149 Replace ............................................................. 182
144 SEBU8371
Maintenance Section
Maintenance Interval Schedule
Every 250 Service Hours of Continuous Swing Gear - Lubricate ....................................... 198
Hammer Use
Every Year
Hydraulic System Oil Filter (Return) - Replace ... 185
Cooling System Coolant Sample (Level 2) -
Initial 500 Hours (for New Systems, Refilled Obtain ............................................................... 162
Systems, and Converted Systems)
Every 3 Years After Date of Installation or
Cooling System Coolant Sample (Level 2) - Every 5 Years After Date of Manufacture
Obtain ............................................................... 162
Seat Belt - Replace ............................................. 195
Every 500 Service Hours
Every 4000 Service Hours or 2 Years
Hydraulic System Oil Sample - Obtain ............... 190
Swing Drive Oil Sample - Obtain ........................ 197 Hydraulic System Oil - Change ........................... 178
Every 500 Service Hours or 3 Months Every 6000 Service Hours or 3 Years
Engine Crankcase Breather - Clean ................... 165 Cooling System Coolant Extender (ELC) - Add .. 159
Engine Oil and Filter - Change ........................... 167
Fuel System Primary Filter (Water Separator) Every 12 000 Service Hours or 6 Years
Element - Replace ............................................ 172
Fuel System Secondary Filter - Replace ............ 173 Cooling System Coolant (ELC) - Change ........... 157
Fuel Tank Cap and Strainer - Clean ................... 174
Every 500 Service Hours of Partial Hammer

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

Hammer Use
Hydraulic System Oil - Change ........................... 178
Every 1000 Service Hours or 6 Months

Battery - Clean .................................................... 145
Battery Hold-Down - Tighten ............................... 145
Boom and Stick Linkage - Lubricate ................... 147
Engine Valve Lash - Check ................................. 169
Final Drive Oil Level - Check .............................. 170
Hydraulic System Oil Filter (Case Drain) -
Replace ............................................................. 182
Swing Drive Oil - Change ................................... 195
Every 1000 Service Hours of Partial Hammer

Use (50% of Service Hours)
Every 1500 Service Hours

Fuel System Third Filter - Replace ..................... 173
Every 2000 Service Hours or 1 Year

Final Drive Oil - Change ..................................... 169
Hydraulic Tank Screen - Clean ........................... 190
Receiver Dryer (Refrigerant) - Replace .............. 194
SEBU8371 145
Maintenance Section
Air Conditioner/Cab Heater Filter (Recirculation) - Inspect/Replace
i02459073 i00993589
Air Conditioner/Cab Heater Battery - Recycle

Filter (Recirculation) - SMCS Code: 1401-561
Inspect/Replace
Always recycle a battery. Never discard a battery.
SMCS Code: 1054-040-A/C; 1054-510-A/C
Always return used batteries to one of the following
NOTICE locations:
An air recirculation filter element plugged with dust will
result in decreased performance and service life to the • A battery supplier
air conditioner or cab heater.
• An authorized battery collection facility
To prevent decreased performance, clean the filter el-
ement, as required. • 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.
i01913589
Battery or Battery Cable -

Illustration 223
g01100988 Inspect/Replace
SMCS Code: 1401-040; 1401-510; 1401-561; 1401;
The air conditioner filter is located on the lower left
1402-040; 1402-510
side of the cab behind the seat.
1. Slide the operator seat forward.
2. Slide the filter element upward. Personal injury can result from battery fumes or
explosion.
3. Tap the air filter in order to remove the dirt. Do not
use compressed air to clean the filter. Batteries give off flammable fumes that can ex-
plode. Electrolyte is an acid and can cause per-
4. After you clean the filter element, inspect the filter sonal injury if it contacts the skin or eyes.
element. If the filter element is damaged or badly
contaminated, use a new filter element. Make sure Prevent sparks near the batteries. Sparks could
that the filter element is dry. cause vapors to explode. Do not allow jumper ca-
ble ends to contact each other or the engine. Im-
5. Install the filter element. proper jumper cable connections can cause an ex-
plosion.
i00934864
Always wear protective glasses when working
Battery - Clean with batteries.
SMCS Code: 1401-070 1. Turn the engine start switch key to the OFF
position. Turn all of the switches to the OFF
Clean the battery surface with a clean cloth. Keep the position.
terminals clean and keep the terminals coated with
petroleum jelly. Install the post cover after you coat 2. Turn the battery disconnect switch to the OFF
the terminal post with petroleum jelly. position. Remove the key.
146 SEBU8371
Maintenance Section
Belt - Inspect/Adjust/Replace
3. Disconnect the negative battery cable at the If new belts are installed, recheck the belt adjustment
battery. after 30 minutes of operation. If two belts or more are
required for an application, replace the belts in belt
4. Disconnect the positive battery cable at the sets. If only one belt of a matched set is replaced, the
battery. new belt will carry more load. This is due to the fact
that the older belts are stretched. The additional load
5. Disconnect the battery cables at the battery on the new belt could cause the new belt to break.
disconnect switch. The battery disconnect switch
is connected to the machine frame.
Water Pump Belt, Fan Drive Belt,
6. Make necessary repairs or replace the battery. and Alternator Belt
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.
10. Install the key and turn the battery disconnect

switch to the ON position.
i02360330
Belt - Inspect/Adjust/Replace
g00686313
Illustration 225
SMCS Code: 1357-025; 1357-040; 1357-510;
1397-025; 1397-040; 1397-510 1. Open the engine hood.
g00937677
Illustration 226
2. Apply approximately 98 N (22 lb) force midway

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

Illustration 224
g00937676 deflect 10 to 12 mm (0.4 to 0.5 inch).
Your engine is equipped with a water pump, with 4. If the deflection is not correct, loosen alternator
a fan drive, and with an alternator. Your engine mounting bolt (1) and bracket bolt (2). Turn
can also be equipped with an air conditioner belt. adjusting bolt (3) in order to adjust the belt tension.
For maximum engine performance and maximum
utilization of your engine, inspect the belts for wear 5. When the adjustment is correct, tighten bolt (1)
and for cracking. Check the belt tension. Adjust the and bolt (2).
belt tension in order to minimize belt slippage. Belt
slippage will decrease the belt life. Belt slippage will 6. Check the deflection of the belt again.
also cause poor performance of the alternator and
of any driven equipment.
SEBU8371 147
Maintenance Section
Boom and Stick Linkage - Lubricate
7. If a new belt is installed, run the engine at i01933858

rated speed for thirty minutes. Check the belt
adjustment. Readjust the belt, if necessary. Boom and Stick Linkage -
Lubricate
Air Conditioner Belt (If Equipped)
SMCS Code: 6501-086; 6502-086
NOTICE Note: Caterpillar recommends the use of 5%
The V-belt must be tensioned correctly. Failure to ten- molybdenum grease for lubricating the boom,
sion the belt properly could cause damage to the belt stick and bucket control linkage. Refer to Special
and/or to the air conditioner compressor. Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” for more information on
molybdenum grease.
Apply lubricant through all fittings after operation

under water.
Wipe all fittings before you apply lubricant.
g01162234
Illustration 227
(4) Nut
(5) Adjusting Bolt
1. Apply approximately 100 N (22 lb) force midway

between the pulleys.
g00685797
2. Measure the deflection of the belt. The belt should Illustration 228
deflect 7 to 10 mm (0.3 to 0.4 inch).
1. Apply lubricant through the fitting at the base of
3. If the deflection is not correct, loosen nut (4). Turn each boom cylinder.
adjusting bolt (5) in order to adjust the belt tension.
4. When the adjustment is correct, tighten nut (4) to

a torque of 38 ± 7 N·m (28 ± 5 lb ft).
5. Check the deflection again.
Note: If a new belt is installed, check the belt

adjustment again after 30 minutes of engine
operation at the rated engine speed.
6. Close the engine hood.
g00685798
Illustration 229
2. The fittings are at the base of the boom. The

fittings can be serviced from the platform on top
of the storage box. To lubricate the lower boom
bearings, apply lubricant through fittings (1) and
(2).
148 SEBU8371
Maintenance Section
Bucket Linkage - Inspect/Adjust
3. Apply lubricant through fittings (3) and (4) for the i02168785
boom cylinder rod.
Bucket Linkage -
4. Apply lubricant through fitting (5) for the stick
cylinder head.
Inspect/Adjust
SMCS Code: 6513-025; 6513-040
Note: To ensure proper lubrication of the lower
boom bearings and of the boom cylinder rod end
bearings, lubricant should be applied through fittings
(1), (2), (3), and (4). Apply lubricant first when the
boom is raised and any attachment is suspended. Unexpected machine movement can cause injury
Then apply lubricant when the boom is lowered and or death.
the attachment is rested on the ground with a slight
downward pressure. To avoid possible machine movement, move the
hydraulic lockout control to the locked position
and attach a Special Instruction, SEHS7332, “Do
Not Operate” or similar warning tag to the hy-
draulic lockout control.
NOTICE
Improperly adjusted bucket clearance could cause
galling on the contact surfaces of the bucket and
stick, resulting in excessive noise and/or damaged
O-ring seals.
g00685799
Illustration 230
5. Apply lubricant through fitting (6). Fitting (6) is at

the connection point of the boom and of the stick.
g00101687
Illustration 232
(1) No gap
(2) Stick boss
(3) Bucket clearance
(4) Shims
(5) Pin
(6) Plate
(7) Bolts
(8) Washers
g00685800 (9) Location
Illustration 231
(10) Flange
(11) Bucket boss
6. Apply lubricant through fitting (7) on the stick
cylinder rod, fitting (8) at the connection point of The clearance of the bucket control linkage on
the boom and of the stick, and fitting (9) at the
this machine can be adjusted by shimming. If the
bucket cylinder head end. gap between the bucket and the stick becomes
excessive, adjust bucket clearance (3) to 0.5 to 1 mm
(.02 to .04 inch).
Two shims of different thickness are used at location

(9). The thicknesses of the shims are 0.5 mm
(0.02 inch ) and 1.0 mm (0.04 inch).
SEBU8371 149
Maintenance Section
Bucket Linkage - Lubricate
i01942324
Bucket Linkage - Lubricate

SMCS Code: 6513-086
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 233
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
contact at no gap (1). This will help to determine
the total clearance of the connection point of the
stick and of the bucket.
3. Place the hydraulic lockout control in the LOCKED g00682908

position and stop the engine. Illustration 234
4. Measure bucket clearance (3), which is the Note: Completely fill all cavities of the bucket control
existing total clearance. linkage with grease when you initially install a bucket.
5. Determine the number of shims that need to be 1. Apply lubricant through fittings for the linkages (1),
removed from shims (4) by using the following (2), (3), and (4).
calculation:
2. Apply lubricant through fittings for the bucket (5),
Subtract 0.5 mm (0.02 inch ) or 1.0 mm (0.04 inch) (6), and (7).
from bucket clearance (3).
Note: Service the above fittings after you operate
6. Remove the appropriate number of shims at the bucket under water.
location (9) in order to meet the above thickness.
Make sure that you use a minimum of three i02781093
0.5 mm (0.02 inch) shims. To remove the shims,
remove bolts (7), washers (8), and plate (6). Bucket Tips - Inspect/Replace
7. After the correct number of shims has been (Drive-through System)
removed and pin (5) is aligned with the pin
hole, install plate (6), washers (8), and bolts (7). SMCS Code: 6805-040; 6805-510
Tighten bolts (7) to a torque of 240 ± 40 N·m
(175 ± 30 lb ft).
8. After installation, make sure that bucket clearance Personal injury or death can result from bucket
(3) is still correct. falling.
Block the bucket before changing bucket tips or

side cutters.
150 SEBU8371
Maintenance Section
Bucket Tips - Inspect/Replace
Bucket Tips Removal Procedure

Note: In order to maximize the life of the bucket tip Note: Retainers are often damaged during the
and the penetration of the bucket tip, the bucket tip removal process. Caterpillar recommends the
can be rotated. installation of a new retainer when bucket tips are
rotated or replaced.
g01055179
Illustration 235
g01054386
Acceptable wear Illustration 238
Internal view
1. The retainer can be removed from the top of the

bucket tip or from the bottom of the bucket tip. Use
one of the following methods in order to remove
the retainer from the bucket tip:
• Use a hammer and a punch in order to drive

out the retainer.
• Use a pin removal tool. Follow step 1.a through

step 1.b for the procedure.
g01055196
Illustration 236
Replace this bucket tip.
Check the bucket tips for wear. If the bucket tip has a
hole, replace the bucket tip.
g01055210
Illustration 239
Pin removal tool
Note: Carefully follow all safety instructions that are

provided with the pin removal tool.
a. Use a hammer and the short punch of the pin

g01053737
removal tool in order to unseat the retainer.
Illustration 237
(1) Bucket tip b. Use a hammer and the long punch of the pin
(2) Retainer removal tool in order to completely remove the
(3) Adapter
retainer from the bucket tip.
SEBU8371 151
Maintenance Section
2. Remove the bucket tip from the adapter with a b. Use a hammer and the short punch of the pin
slight counterclockwise rotation. removal tool in order to ensure that the latch of
the retainer is properly seated into the recess
Installation Procedure of the bucket tip.
1. Clean the adapter, if necessary.
2. Install the new bucket tip or the rotated bucket tip

onto the adapter with a slight clockwise rotation.
g01054753
Illustration 242
A properly installed retainer does not extend beyond the ear of
the bucket tip.
4. The retainer is properly seated if the retainer can

Illustration 240
g01053732 be moved slightly by the technician’s hand. If the
retainer cannot be moved, use the punch or the
Proper location for installing the retainer
pin removal tool in order to adjust the retainer,
as needed. The ends of the retainer should not
extend beyond the ear of the bucket tip.
Side Cutters (If Equipped)
g01053731
Illustration 241
Internal View
The latch of the retainer is properly seated in the recess of the
bucket tip.
g01092808
3. The retainer can be installed from the top of the Illustration 243
bucket tip or from the bottom of the bucket tip. Use Bucket with side cutters
one of the following methods in order to install the (A) Side cutters
retainer into the bucket tip:
1. Remove the mounting bolts and the side cutters.
• Use a hammer in order to drive the retainer into
the bucket tip. A punch may be necessary in 2. Clean the mounting surface of the side plate on
order to ensure that the latch of the retainer is the bucket and of the side cutter. Remove any
properly seated into the recess of the bucket tip. burrs or protrusions on the mating surfaces.
• Use a pin removal tool. Follow step 3.a through

step 3.b for the procedure.
a. Use a hammer in order to drive the retainer

into the bucket tip.
152 SEBU8371
Maintenance Section
g01389435 g01389452
Illustration 244 Illustration 246
(4) Side cutter
Note: Some side cutters may be rotated for additional

wear.
3. Install the side cutter.
Note: Certain bolts may require thread compound.
4. Hand tighten the bolts.
g01389453
Illustration 247
(8) Side plate
(9) Retainer
(10) Side protector
(11) Pin
1. Hit pin (11) from the retainer side of the bucket

in order to remove side protector (10) from side
plate (8).
g01389433
2. Clean side protector (10), pin (11), retainer (9) and
Illustration 245 side plate (8) before installation.
Section B-B From Illustration 244
(4) Side cutter 3. Put retainer (9) in side plate (8).
(5) Side plate on a bucket
(6) 0.0 mm (0.0 inch) 4. Align two pin holes of the new protector and the
(7) Shear ledge on a side cutter
side plate. Hit the pin from the side of the bucket
without the retainer.
5. Make sure that there is not a gap between the
side plate on the bucket and the shear ledge on
Note: If the pin and/or the retainer are worn, replace
the side cutter. the pin and/or the retainer.
6. Torque the mounting bolts to the correct
specification.
Side Protectors (If Equipped)

Inspect the wear of the side protector. When too
much wear is present, replace the protector.
SEBU8371 153
Maintenance Section
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 249
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 248
(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 250
• 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.
154 SEBU8371
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 254
Final assembly of pin into bucket tip.
e. Strike the end of the tool until the pin is fully

inserted.
g01209166
Illustration 252
(8) Pin
a. Insert pin (8) through the bucket tip.

SEBU8371 155
Maintenance Section
Side Cutters
g01092812
Illustration 257
g01092808
Illustration 255 Section B-B From Illustration 256
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 256
(A) Side cutter
Note: Some side cutters may be rotated for additional

wear.
3. Install the side cutter.

g00851494
Illustration 258
Note: Certain bolts may require thread compound.
4. Hand tighten the bolts.

156 SEBU8371
Maintenance Section
Cab Air Filter (Fresh Air) - Clean/Replace
The cab air filter is behind the cab.
1. Loosen bolt (1) and open filter cover (2).
g00851496
Illustration 259
(11) Side protector
(12) Pin
(13) Retainer g00730032
Illustration 261
(14) side plate
(2) Filter cover
(3) Air filter
1. Hit pin (12) from the retainer side of the bucket
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) 3. Clean the air filter with a maximum of 200 kPa
and side plate (14) before installation. (30 psi) pressure air.
3. Put retainer (13) in side plate (14). 4. After you clean the air filter, inspect the air filter.
If the air filter is damaged or badly contaminated,
4. Align two pin holes of the new protector and the use a new air filter.
side plate. Hit the pin from the side of the bucket
without the retainer. 5. Install the air filter and the filter cover.
Note: If the pin and/or the retainer are worn, replace Note: Make sure that the arrow on top of the air filter
the pin and/or the retainer. is facing forward.
i02465602
i01547055
Cab Air Filter (Fresh Air) - Circuit Breakers - Reset

Clean/Replace SMCS Code: 1420-529
SMCS Code: 7342-070; 7342-510 Open the access door on the left side of the machine.
g00730030 g01120975
(1) Bolt
(2) Filter cover
SEBU8371 157
Maintenance Section
Condenser (Refrigerant) - Clean
Main Breaker (1) – This circuit breaker is designed

to protect the electrical system. The circuit breaker
has a capacity of 80 Amp.
Air Inlet Heater Circuit (2) – This circuit breaker is

designed to protect the air inlet heater. The circuit
breaker has a capacity of 120 Amp.
Alternator Circuit (3) – 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 g00537515

to reset the circuit breaker. If the electrical system is Illustration 264
working properly, the button will remain depressed. Typical example
If the button does not remain depressed, check the
appropriate electrical circuit. Repair the electrical 2. Inspect the condenser for debris. Clean the
circuit, if necessary. condenser, if necessary.
3. Use clean water to wash off all dust and dirt from
i01041005 the condenser.
Condenser (Refrigerant) - 4. Close the access door.
Clean
i02582005
SMCS Code: 1805-070
Cooling System Coolant (ELC)
NOTICE
If excessively dirty, clean condenser with a brush. To - Change
prevent damage or bending of the fins, do not use a
stiff brush. SMCS Code: 1350-044
Repair the fins if found defective.
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

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

Illustration 263
g00102191 the coolant is hot, the hose can come off causing
burns.
1. Open the access door on the left side of the
machine. Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
158 SEBU8371
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 266
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 265
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”
SEBU8371 159
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
steam. Any contact can cause severe burns.
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

the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.

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 267
(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.

160 SEBU8371
Maintenance Section
Cooling System Coolant Level - Check
3. Unlatch the engine hood and raise the engine i02580035

hood.
Cooling System Coolant Level
- Check
SMCS Code: 1350-040; 1350-535-FLV;
1395-535-FLV

and alkali.
At operating temperature, engine coolant is hot

to heaters or the engine contain hot coolant or
g00544510
Illustration 268 steam. Any contact can cause severe burns.
4. Make sure that the cooling system has cooled Remove cooling system pressure cap slowly to
down. Loosen the cooling system pressure relieve pressure only when engine is stopped and
cap slowly in order to relieve system pressure. cooling system pressure cap is cool enough to
Remove the pressure cap. touch with your bare hand.
Note: Refer to Operation and Maintenance Manual, Do not attempt to tighten hose connections when
“General Hazard Information” for information on the coolant is hot, the hose can come off causing
containing fluid spillage. burns.
5. It may be necessary to drain some coolant from Cooling System Coolant Additive contains alkali.
the radiator so that Caterpillar Extender can be Avoid contact with skin and eyes.
added to the cooling system.
1. Open the left rear access door.
Note: Always discard drained fluids according to
local regulations.
6. Add Caterpillar Extended Life Coolant (ELC) to

the cooling system. Refer to the following topics
for the proper amount of Caterpillar Extender:

Machine Fluids Recommendations”
• Operation and Maintenance Manual, “Capacities

(Refill)”
7. Inspect the gasket of the cooling system pressure

cap. If the gasket is damaged, replace the
pressure cap. Illustration 269
g00545226
(1) “FULL” level

8. Install the cooling system pressure cap. (2) “LOW” level
9. Close the engine hood and latch the engine hood. 2. Check the coolant level of the coolant reservoir.
Maintain the coolant level between the “FULL”
mark and the “LOW” mark. If the coolant reservoir
is empty, follow Steps 2.a through 2.i.
a. Unlatch the engine hood and raise the engine

hood.
SEBU8371 161
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
5. Close the left access door.
i02250847

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
g00544510
a Coolant Sample (Level 2) that is obtained at
Illustration 270 the recommended interval that is stated in the
Maintenance Interval Schedule.
b. Slowly loosen the cooling system pressure cap
in order to relieve system pressure. Remove Note: Obtain a Coolant Sample (Level 1) if the
the pressure cap. cooling system is filled with any other coolant
instead of Cat ELC. This includes the following
Note: Refer to Operation and Maintenance Manual, types of coolants.
“General Hazard Information” for information on
containing fluid spillage. • Commercial long life coolants that meet the
Caterpillar Engine Coolant Specification -1
c. Add the appropriate coolant solution to the (Caterpillar EC-1)
cooling system. Refer to the following topics:
• Cat Diesel Engine Antifreeze/Coolant (DEAC)
Machine Fluids Recommendations” • Commercial heavy-duty coolant/antifreeze
• Operation and Maintenance Manual, NOTICE
“Capacities (Refill)”
Always use a designated pump for oil sampling, and
d. Start the engine. Operate the engine without use a separate designated pump for coolant sampling.
the cooling system pressure cap until the water Using the same pump for both types of samples may
temperature regulator opens and the coolant contaminate the samples that are being drawn. This
level stabilizes. contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
e. Maintain the coolant level within 13 mm dealers and customers.
(0.5 inch) of the bottom of the filler pipe.
Note: Level 1 results may indicate a need for
f. Inspect the condition of the gasket on the Level 2 Analysis.
pressure cap. If the gasket is damaged, replace
the pressure cap.
NOTICE
Care must be taken to ensure that fluids are contained
g. Install the cooling system pressure cap.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
h. Stop the engine.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
i. Close the engine hood and latch the engine
nent containing fluids.
hood.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
containing fluid spillage.
products.
3. If additional coolant is necessary, remove the
Dispose of all fluids according to local regulations and
reservoir cap and add the appropriate coolant
mandates.
solution.
4. Install the reservoir cap.

162 SEBU8371
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
i02049802

Sample (Level 2) - Obtain
SMCS Code: 1395-008; 1395-554; 7542
Reference: Refer to Operation and Maintenance

Manual, “Cooling System Coolant Sample (Level 1)
- Obtain” for the guidelines for proper sampling of
the coolant.
Obtain the sample of the coolant as close as possible

to the recommended sampling interval. Supplies
Illustration 271
g00811362 for collecting samples can be obtained from your
Caterpillar dealer.
A typical example is shown.
Submit the sample for Level 2 analysis.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order Reference: For additional information about coolant
to receive the full effect of S·O·S analysis, you analysis, refer to Special Publication, SEBU6250,
must establish a consistent trend of data. In order “Caterpillar Machine Fluids Recommendations” or
to establish a pertinent history of data, perform consult your Caterpillar dealer.
consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer. i02530911
Use the following guidelines for proper sampling of Engine Air Filter Primary
the coolant: Element - Clean/Replace
• Complete the information on the label for the SMCS Code: 1054-070; 1054-510
sampling bottle before you begin to take the
samples. If a warning and a pictograph is displayed on the
message display or if the exhaust is black, check the
• Keep the unused sampling bottles stored in plastic primary filter.
bags.
1. Open both access doors on the left side of the
• Obtain coolant samples directly from the coolant machine.
sample port. You should not obtain the samples
from any other location.
• Keep the lids on empty sampling bottles until you

are ready to collect the sample.
• Place the sample in the mailing tube immediately

after obtaining the sample in order to avoid
contamination.
• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.
Submit the sample for Level 1 analysis.
g01266485
Illustration 272
For additional information about coolant analysis, see
Special Publication, SEBU6250, “Caterpillar Machine 2. Squeeze the outlet tube (1) slightly in order to
Fluids Recommendations” or consult your Caterpillar purge the dirt from the outlet tube.
dealer.
SEBU8371 163
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
g01266486 g00101416
3. Loosen the cover latches (2) and remove the air Note: Install the air cleaner cover properly. The
cleaner cover. arrows must point upward.
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.
10. Close the access doors.
Cleaning Primary Air Filter

g00101415
Elements
Illustration 274
NOTICE
4. Remove the primary filter element from the air Caterpillar recommends certified air filter cleaning ser-
cleaner housing. vices available at participating Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
5. Clean the air cleaner cover and the inside of the to assure consistent quality and sufficient filter life.
air cleaner housing.
Observe the following guidelines if you attempt to
6. Inspect the O-ring seal on the air cleaner cover. clean the filter element:
Replace the O-ring seal if the O-ring seal is worn
or damaged. Do not tap or strike the filter element in order to re-
move dust.
7. Install the clean primary filter.
Do not wash the filter element.
Note: Refer to “Cleaning Primary Air Filter Elements”.
Use low pressure compressed air in order to remove
8. Install the air cleaner cover and close the latches the dust from the filter element. Air pressure must not
securely. exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets, or

seals. Dirt entering the engine will cause damage to
engine components.
164 SEBU8371
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
When the primary air filter element is cleaned, check Aim the hose so that the air flows inside the element
for rips or tears in the filter material. Replace the along the length of the filter in order to help prevent
primary air filter element after the primary air filter damage to the paper pleats. Do not aim the stream of
element has been cleaned six times. The primary air air directly at the primary air filter element. Dirt could
filter element should be replaced at least one time be forced further into the pleats.
per year. This replacement should be performed
regardless of the number of cleanings. Vacuum Cleaning
NOTICE Vacuum cleaning is another method for cleaning
Do not clean the air filter elements by bumping or tap- primary air filter elements which require daily cleaning
ping. This could damage the seals. Do not use ele- because of a dry, dusty environment. Cleaning with
ments with damaged pleats, gaskets, or seals. Dam- pressurized air is recommended prior to vacuum
aged elements will allow dirt to pass through. Engine cleaning. Vacuum cleaning will not remove deposits
damage could result. of carbon and oil.
Visually inspect the primary air filter elements before Inspecting the Primary Air Filter
cleaning. Inspect the air filter elements for damage Elements
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
Pressurized Air
Pressurized air can be used to clean primary air filter
elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of g00281693
Illustration 277
carbon and oil. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi).
Inspect the clean, dry primary air filter element. Use
a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air filter
element. Rotate the primary air filter element. Inspect
the primary air filter element for tears and/or holes.
Inspect the primary air filter element for light that may
show through the filter material. If it is necessary in
order to confirm the result, compare the primary air
filter element to a new primary air filter element that
has the same part number.
Do not use a primary air filter element that has any

tears and/or holes in the filter material. Do not use
a primary air filter element with damaged pleats,
gaskets or seals. Discard damaged primary air filter
Illustration 276
g00281692 elements.
Note: When the primary air filter elements are Storing Primary Air Filter Elements
cleaned, always begin with the clean side (inside)
in order to force dirt particles toward the dirty side If a primary air filter element that passes inspection
(outside). will not be used, the primary air filter element can
be stored for future use.
SEBU8371 165
Maintenance Section
Engine Air Filter Secondary Element - Replace
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 278
Do not use paint, a waterproof cover, or plastic as a

protective covering for storage. An air flow restriction
may result. To protect against dirt and damage, wrap
the primary air filter elements in Volatile Corrosion Illustration 279
g00101451
Inhibited (VCI) paper.
3. Remove the secondary filter element.
Place the primary air filter element into a box for
storage. For identification, mark the outside of the 4. Cover the air inlet opening. Clean the inside of
box and mark the primary air filter element. Include the air cleaner housing.
the following information:
5. Remove the cover from the air inlet opening.
• Date of cleaning
6. Install the new secondary filter element.
• Number of cleanings
7. Install the primary filter element.
Store the box in a dry location.
8. Install the air cleaner cover and close the latches
i01430699
securely.
Engine Air Filter Secondary 9. Close the access door.

Element - Replace
i01584904
SMCS Code: 1054-510
Engine Crankcase Breather -
NOTICE Clean
Always replace the secondary filter element. Never at-
tempt to reuse the secondary filter element by clean- SMCS Code: 1317-070-DJ
ing the element.
1. Open the engine hood.
When the primary filter element is replaced, the sec-
ondary filter element should be replaced.
The secondary filter element should also be replaced

if the air filter restriction warning appears on the mes-
sage display after the installation of a clean primary
filter element or if exhaust smoke is still black.
1. Open the access door on the front left side of the

machine.
166 SEBU8371
Maintenance Section
Engine Oil Level - Check
Note: This machine is equipped with both an

automated function for checking fluid levels and
a dipstick. Refer to Operation and Maintenance
Manual, “Monitoring System” regarding the
automated system. If the machine is on an incline or
the engine has been stopped only for a short time,
then the engine oil does not return to the crankcase
and the fluid level cannot be properly checked by
either method. Park the machine on level ground and
check the oil level after the engine has been stopped
for at least 30 minutes.
Check the oil level while the engine is stopped. Do

not check the oil level while the engine is running.
g00824179
Illustration 280 1. Open the hood.
2. Loosen hose clamp (2) and disconnect outlet hose
(1) from breather (3).
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).
i02606949
Engine Oil Level - Check

g01343821
Illustration 281
SMCS Code: 1000-535
2. Remove the dipstick (1). Wipe the oil off the
dipstick (1) and insert the dipstick (1).
Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact skin.
NOTICE
Do not overfill the crankcase. Engine damage can re-
sult.
g00824185
Illustration 282
3. Remove the dipstick (1) and check the dipstick

(1). The oil level should be between the “H” mark
and the “L” mark.
SEBU8371 167
Maintenance Section
Engine Oil Sample - Obtain
i02720177
NOTICE
Operating your engine when the oil level is above the
Engine Oil Sample - Obtain
“H” mark could cause the crankshaft to dip into the oil.
SMCS Code: 1000-008; 1000; 1348-008;
This could lead to excessively high oil temperatures
1348-554-SM; 7542-008; 7542-554-OC, SM
which can reduce the lubricating characteristics of the
oil, lead to bearing damage, and could result in loss of
engine power.
g00751728
Illustration 284
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,
“S·O·S 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
g01343836 sample of the engine oil.
Illustration 283
Note: Refer to Operation and Maintenance Manual, i02720183

Containing Fluid Spillage. Engine Oil and Filter - Change
4. Remove the oil filler plug (2) in order to add oil, SMCS Code: 1318-510
if necessary. See Operation and Maintenance
Manual, “Lubrication Viscosity”.
Note: If the oil is deteriorated or badly contaminated, Hot oil and hot components can cause personal
change the oil regardless of the maintenance interval. injury. Do not allow hot oil or hot components to
contact skin.
5. Clean the oil filler plug (2). Install the oil filler plug
(2).
Note: If the sulfur content in the fuel is greater than
6. Close the hood. 1.5% by weight, use an oil that has a TBN of 30 and
reduce the oil change interval by one-half.
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.
168 SEBU8371
Maintenance Section
Engine Oil and Filter - Change
g00101627 g01365879
1. The drain valve for the engine crankcase oil is 5. Remove the oil filter. See Operation and
located under the rear of the upper structure. Maintenance Manual, “Oil Filter - Inspect”. Discard
the used oil filter properly.
“General Hazard Information” for information on 6. Clean the filter housing base. Make sure that all of
Containing Fluid Spillage. the former filter gasket is removed.
7. Apply a thin coat of engine oil to the gasket of

the new filter.
8. Install the new oil filter by hand.
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 instructions that are provided by the
supplier of the filter.
g00937651
Illustration 286
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.
4. Open the access door on the right side of the

g01365881
machine. Illustration 288
(1) Dipstick
SEBU8371 169
Maintenance Section
Engine Valve Lash - Check
i01747875
Engine Valve Lash - Check

SMCS Code: 1102-082; 1102-535; 1102; 1105-025;
1105-535; 1121-535; 1209-082; 1209-535; 1209;
7527
Refer to Engine Systems Operation/Testing and

Adjusting in order to perform the complete procedure
for the valve lash adjustment.
i02580062
Final Drive Oil - Change

SMCS Code: 4050-044-FLV
g01365841
Illustration 289 injury. Do not allow hot oil or hot components to
(2) Oil filler plug contact skin.
9. Remove oil filler plug (2). Fill the crankcase

with new oil. See Operation and Maintenance
Manual, “Capacities (Refill)” and Operation and
Maintenance Manual, “Lubricant Viscosities”.
Clean the oil filler plug and install the oil filler plug.
NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
10. Start the engine and allow the oil to warm. Check
the engine for leaks. Stop the engine.
g00822278
Illustration 291
(1) Oil level plug
(2) Oil drain plug
1. Position one final drive so that oil drain plug (2) is

at the bottom.

Containing Fluid Spillage.
2. Remove drain plug (2) and level plug (1). Allow

the oil to drain into a suitable container.
g00104116
Illustration 290
3. Clean the plugs and inspect the O-ring seals. If
wear or damage is evident, replace the drain plug,
11. Wait for 30 minutes in order to allow the oil to the level plug, and/or the O-ring seals.
drain back into the crankcase. Check the oil level
with dipstick (1). Maintain the oil between the “H” 4. Install drain plug (2).
and “L” marks on the dipstick. If necessary, add oil.
12. Close the access door.

170 SEBU8371
Maintenance Section
Final Drive Oil Level - Check
5. Fill the final drive to the bottom of the opening on Note: Refer to Operation and Maintenance Manual,
level plug (1). See Operation and Maintenance “General Hazard Information” for information on
Manual, “Lubricant Viscosities” and Operation and Containing Fluid Spillage.
Maintenance Manual, “Capacities (Refill) ”.
2. Remove oil level plug (1).
6. Install level plug (1).
3. Check the oil level. The oil should be near the
7. Perform Step 1 to Step 6 on the other final drive. bottom of the level plug opening.
Use a different container for the oil so that the oil
samples from the final drives will be separate. 4. Add oil through the level plug opening, if
necessary. See Operation and Maintenance,
8. Completely remove the oil that has spilled onto “Lubricant Viscosities”.
surfaces.
Note: Overfilling the final drive will cause the seals on
9. Start the engine and allow the final drives to run the travel motor to allow hydraulic oil or water to enter
through several cycles. the final drive. This may contaminate the final drive.
10. Stop the engine. Check the oil level. 5. Clean oil level plug (1). Inspect the O-ring seal.
Replace the O-ring seal if the O-ring seal is worn
11. Check the drained oil for metal chips or for or damaged.
particles. If there are any chips or particles, consult
your Caterpillar dealer. 6. Install oil level plug (1).
12. Properly dispose of the drained material. Obey 7. Repeat the procedure for the other final drive.
local regulations for the disposal of the material.
i02580071
Final Drive Oil Sample - Obtain

i02580064
Final Drive Oil Level - Check

SMCS Code: 4011-008; 4050-008; 4050-SM;
SMCS Code: 4050-535-FLV 7542-008
Hot oil and hot components can cause personal Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to injury. Do not allow hot oil or hot components to
contact skin. contact skin.
g00822278 g00822278
(1) Oil level plug (1) Oil level plug
(2) Oil drain plug (2) Oil drain plug
1. Position one final drive so that oil drain plug (2) is 1. Position the final drive so that oil drain plug (2) is
at the bottom. at the bottom.
SEBU8371 171
Maintenance Section
Fuel System - Prime

2. Remove oil level plug (1).
3. Obtain a sample of the final drive oil through the

hole for the oil level plug.
4. Install oil level plug (1).
Refer to Special Publication, SEBU6250, “Caterpillar

Machine Fluids Recommendations”, “S·O·S Oil
Analysis” for more information on obtaining a sample
of the final drive oil. For additional information about
taking an oil sample, refer to Special Publication,
PEHP6001, “How To Take A Good Oil Sample”.
i02674917
Fuel System - Prime g01344046

Illustration 294
SMCS Code: 1250-548 (1) Air vent
(2) Air vent
(3) Secondary fuel filter
(4) Priming pump plunger
(5) Third fuel filter
Personal injury or death may result from failure to
adhere to the following procedures. Note: Refer to Operation and Maintenance Manual,
Fuel leaked or spilled onto hot surfaces or electri- containing fluid spillage.
cal components can cause a fire.
2. Loosen air vent (1) on the secondary fuel filter (3).
Clean up all leaked or spilled fuel. Do not smoke
while working on the fuel system. 3. Rotate priming pump plunger (4) in a
counterclockwise rotation. Rotate the plunger
Turn the disconnect switch OFF or disconnect the until the plunger becomes unlocked. Operate the
battery when changing fuel filters. priming pump plunger.
4. Tighten air vent (1) when the fuel flow is free of

1. Open the engine hood. air bubbles.
5. Loosen air vent (2) on the third fuel filter (5).
6. Operate priming pump plunger (4).
7. Tighten air vent (2) when the fuel flow is free of

air bubbles.
8. Push the plunger (4) inward and rotate the plunger

clockwise.
172 SEBU8371
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
i02540566 Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” that pertains to
Fuel System Primary Filter containing fluid spillage.
(Water Separator) Element - 3. Drain the water and sediment into a suitable
Replace container.
SMCS Code: 1263-510-FQ Note: Dispose of drained fluids and used filters
according to local regulations.
4. Close drain valve (3).

Personal injury or death may result from failure to
adhere to the following procedures. 5. Hold the bottom of the filter (1) while you loosen
bowl (2).
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. 6. Remove bowl (2).
Clean up all leaked or spilled fuel. Do not smoke 7. Remove filter (1). Discard filter(1).
while working on the fuel system.
8. Clean the inside surface of the filter head and of
Turn the disconnect switch OFF or disconnect the bowl (2).
battery when changing fuel filters.
9. Inspect the O-ring on bowl (2). Also inspect the
seal on the filter head. Replace these seals if the
NOTICE seals are worn or damaged.
Do not fill the fuel filters with fuel before installing the
fuel filters. The fuel will not be filtered and could be 10. Lubricate the seal of the new element with clean
contaminated. Contaminated fuel will cause acceler- diesel fuel.
ated wear to fuel system parts.
11. Install the new filter by hand.
The primary filter/water separator is located behind Instructions for the installation of the filter are
the left rear access door. printed on the side of each Caterpillar spin-on
filter. For non-Caterpillar filters, refer to the
1. Open the rear access door on the left side of the installation instructions that are provided by the
machine. supplier of the filter.
12. Install bowl (2).
13. Prime the fuel system. See Operation and

Maintenance Manual, “Fuel System - Prime” for
instructions.
g01102123
Illustration 295
(1) Filter
(2) Bowl
(3) Drain valve
2. Turn drain valve (3) counterclockwise in order to

open. The drain valve is located on the bottom
of the water separator.
SEBU8371 173
Maintenance Section
Fuel System Secondary Filter - Replace
i02700087 4. Apply clean diesel fuel to the seal of the new fuel
filter.
Fuel System Secondary Filter -
Replace 5. Install the new fuel filter hand tight until the seal of
the fuel filter contacts the filter mounting base.
SMCS Code: 1261-510
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
instructions that are provided by the supplier of the
Personal injury or death may result from failure to filter.
adhere to the following procedures.
Note: You may need to use a Caterpillar strap
Fuel leaked or spilled onto hot surfaces or electri- wrench, or another suitable tool, in order to turn
cal components can cause a fire. the filter to the amount that is required for final
installation. Make sure that the installation tool does
Clean up all leaked or spilled fuel. Do not smoke not damage the filter.
Turn the disconnect switch OFF or disconnect the Maintenance Manual, “Fuel System - Prime” for
battery when changing fuel filters. instructions.

NOTICE
Turn the disconnect switch OFF or disconnect the bat-
tery when changing fuel filters. i02700131
Do not fill fuel filters with fuel before installing them. Fuel System Third Filter -
Contaminated fuel will cause accelerated wear to fuel
systems parts.
Replace
SMCS Code: 1261-510
1. Open the engine hood.

“General Hazard Information” for information on Personal injury or death may result from failure to
containing fluid spillage. 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

Turn the disconnect switch OFF or disconnect the

battery when changing fuel filters.
NOTICE
Turn the disconnect switch OFF or disconnect the bat-
tery when changing fuel filters.
g01354318
Illustration 296 Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
2. Remove the filter. systems parts.
Note: Always discard used filters according to local

regulations. 1. Open the engine hood.
3. Clean the filter mounting base. Make sure that all Note: Refer to Operation and Maintenance Manual,
of the old filter seal is removed. “General Hazard Information” for information on
174 SEBU8371
Maintenance Section
Fuel System Water Separator - Drain

g01354352
Illustration 297
2. Remove the filter.

g00751973
Illustration 298
Note: Always discard used filters according to local (1) Drain valve
regulations. (2) Bowl
3. Clean the filter mounting base. Make sure that all 3. Check bowl (2) in the bottom of the water
of the old filter seal is removed. separator. Open drain valve (1). Drain the water
and sediment in the bowl.
4. Apply clean diesel fuel to the seal of the new fuel
filter. Note: Dispose of used fluids according to local
regulations.
5. Install the new fuel filter hand tight until the seal of
the fuel filter contacts the filter mounting base. 4. Close drain valve (1).
Note: Instructions for the installation of the filter are 5. Close the rear access door.
printed on the side of each Caterpillar spin-on filter.
For non-Caterpillar filters, refer to the installation
instructions that are provided by the supplier of the i01589598
filter.
Fuel Tank Cap and Strainer -
Note: You may need to use a Caterpillar strap Clean
wrench, or another suitable tool, in order to turn
the filter to the amount that is required for final SMCS Code: 1273-070-STR
installation. Make sure that the installation tool does
not damage the filter.

Maintenance Manual, “Fuel System - Prime” for
instructions.
i02529331
Fuel System Water Separator

- Drain
g00824193
SMCS Code: 1263 Illustration 299
1. Open the rear access door on the left side of the 1. Remove the fuel cap.
machine.
2. Inspect seal (4) for damage. Replace the seal, if
2. Provide a suitable container for used fluid. necessary.
SEBU8371 175
Maintenance Section
Fuel Tank Water and Sediment - Drain
3. Remove screws (1), filter assembly (2), drain

valve (3) and the gaskets.
g01043694
Illustration 301
Illustration 300
g00824196 Note: Refer to Operation and Maintenance Manual,
Note: Refer to Operation and Maintenance Manual, containing fluid spillage.
Containing Fluid Spillage. 2. Open the drain valve by turning the valve
counterclockwise. Allow the water and the
4. Remove the strainer that is located in the filler sediment to drain into a suitable container.
opening.
Note: Dispose of drained fluids according to local
5. Wash the strainer and the fuel tank cap in a clean, regulations.
nonflammable solvent.
3. Close the drain valve by turning the valve
6. Install a new cap filter kit. Install the gaskets, drain clockwise.
valve (3), filter assembly (2), and screws (1).
7. Install the strainer into the filler opening.
i02362302
8. Install the fuel tank cap.
Fuses - Replace
i02709049
SMCS Code: 1417-510
Fuel Tank Water and Sediment
- Drain
SMCS Code: 1273-543
The fuel tank drain valve is located underneath the

main hydraulic pump.

machine.
g01101038
Illustration 302
The fuse panel is located on the right side of the

interior storage box. Remove the cover in order to
access the fuses.
176 SEBU8371
Maintenance Section
Fuses - Replace
Fuses – Fuses protect the electrical

system from damage that is caused by
overloaded circuits. Change a fuse if the
element separates. If the element of a new fuse
separates, check the circuit and/or repair the circuit.
NOTICE
Always replace fuses with the same type and capacity
fuse that was removed. Otherwise, electrical damage
could result.
NOTICE
If it is necessary to replace fuses frequently, an elec-
trical problem may exist.
Contact your Caterpillar dealer.
To replace a fuse, use the puller that is stored in the

fuse panel. Two fuses of 5 Amperes, three fuses of
10 Amperes, two fuses of 15 Amperes, and one fuse
of 30 Amperes are contained in the fuse panel as
spare fuses.
The following list identifies the circuits that are

protected by each fuse. The amperage for each fuse
is included with each circuit.
g01179985
Illustration 303
(1) Air Conditioner – 15 Amp
(2) Automatic Engine Speed Control (AEC) – 5

Amp
(3) Chassis Light – 10 Amp
(4) Cigar Lighter – 10 Amp
(5) 12 Volt 7 Amp Converter – 10 Amp
(6) Switch Panel And Radio – 5 Amp
(7) Attachment Solenoid – 10 Amp
(8) Seat Heater – 5 Amp
(9) Lower Window Wiper and Window Washer –

10 Amp
(10) Window Wiper and Window Washer – 10 Amp
(11) Air Suspension Seat – 10 Amp
(12) 12 Volt 7 Amp Converter – 10 Amp

SEBU8371 177
Maintenance Section
High Intensity Discharge Lamp (HID) - Replace
(13) Beacon – 10 Amp i02245859
(14) Inspection Lamp 2 – 10 Amp High Intensity Discharge Lamp

(15) Boom Float – 5 Amp
(HID) - Replace
(If Equipped)
(16) Spare – 5 Amp
SMCS Code: 1434-510

HID lamps operate at very high voltages. To avoid
(19) Spare – 10 Amp electrical shock and personal injury, disconnect
power before servicing HID lamps.
(21) Heater and Air Conditioner Blower Fan – 15

Amp
HID bulbs become very hot during operation.
(22) Product Link – 5 Amp Before servicing, remove power from lamp for at
least five minutes to ensure lamp is cool.
(23) Boom Light – 10 Amp
(24) Air Conditioner Condenser Blower – 10 Amp NOTICE

Although HID bulb materials may change over time,
(25) Cab Light – 10 Amp HID bulbs produced at the time of the printing of this
manual contain mercury. When disposing of this com-
(26) Cab Dome Light and Radio Memory – 10 Amp ponent, or any waste that contains mercury, please
use caution and comply with any applicable laws.
(27) Engine Start Switch – 10 Amp
(28) Horn – 10 Amp 1. Remove the electrical power from the high
intensity discharge lamp (HID). The electrical
(29) Machine Control Module – 15 Amp power must be removed from the HID lamp for
at least five minutes, in order to ensure that the
(30) Engine Control Module (ECM) – 15 Amp bulb is cool.
(31) Inspection Lamp 2 – 10 Amp 2. Disassemble the housing for the HID lamp in order
to have access to the bulb.
(32) Inspection Lamp 3 – 10 Amp
Note: On some HID lamps, the bulb is an integral
(33) Electric Refueling Pump – 30 Amp part of the lens assembly. The bulb is not removed
separately from the lens assembly. Replace the
(34) Spare – 5 Amp entire lens assembly on these HID lamps.
(35) Spare – 10 Amp 3. Remove the bulb from the HID lamp.
(36) Spare – 10 Amp 4. Install the replacement bulb in the HID lamp.
(37) Spare – 10 Amp If the bulb is an integral part of the lens assembly,
install the replacement lens assembly in the HID
(38) Spare – 10 Amp lamp.
(39) Spare – 15 Amp Note: In order to avoid failure to the bulb that is
premature, avoid touching the bulb’s surface with
(40) Spare – 30 Amp your bare hands. Clean any fingerprints from the bulb
with alcohol prior to operation.
5. Reassemble the housing for the HID lamp. Ensure

that any printing on the lens is oriented correctly
with respect to the HID lamp’s mounting position
on the machine.
178 SEBU8371
Maintenance Section
Hydraulic System Oil - Change
6. Reattach the electrical power to the HID lamp. • Engine oils that meet the Cat ECF-1 specification
7. Check the HID lamp for proper operation. • API CG-4
Note: Consult your Caterpillar dealer for additional • API CF
information on HID lamps.
• TO-4
i02581938
Note: Industrial hydraulic oils are not recommended
Hydraulic System Oil - Change for the hydraulic systems of Caterpillar machines.
Industrial hydraulic oils are more likely to allow
SMCS Code: 5056-044 corrosion and Industrial hydraulic oils are more likely
to allow excessive wear.
4000 Hour Oil Change Interval Procedure to Change the Hydraulic

A 4000 hour maintenance interval for hydraulic Oil
oil (change) is available. The extended interval
requires S·O·S monitoring of the hydraulic oil. The
interval for S·O·S monitoring is every 500 hours. The
maintenance interval for the hydraulic oil filter is not
changed. If S·O·S monitoring is not performed, the
2000 hour maintenance interval must be used.
contact skin.
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
Maintenance Interval Schedule.
Lubricants
Approved hydraulic oil must be used to obtain the
4000 hour hydraulic oil change. Refer to the list that
follows for approved oils.
g00101435
Illustration 304
Caterpillar Hydraulic Oils
1. Park the machine on level ground. Lower the
• Cat HYDO bucket to the ground so that the stick is vertical.
• Cat TDTO 2. Open the engine access cover.
• Cat TDTO-TMS
• Cat DEO
• Cat BIO HYDO (HEES) (Biodegradable Hydraulic
Oil)
• Cat MTO
Commercial Oils
Diesel engine oils (Heavy Duty) with a minimum

zinc content of 900 ppm can be used. Acceptable
commercial oils are identified by the American
Petroleum Institute trademark (API) . Refer to the list Illustration 305
g01121186
that follows for acceptable types of hydraulic oils.
SEBU8371 179
Maintenance Section
3. Remove bolts (1), washers (2), and cover (3) from

the top of the hydraulic tank.
g00687273
Illustration 308
(4) Plug
g01121188
Illustration 306
4. Clean the area thoroughly in order to keep dirt out “General Hazard Information” for information that
of the screen cover. Clean the area thoroughly in pertains to containing fluid spillage.
order to keep dirt out of the fill/vent plug.
7. Remove plug (4).
5. Relieve the internal pressure from the hydraulic
tank by loosening the fill/vent plug. After the
pressure is relieved, remove the fill/vent plug.
g00101446
Illustration 307
The oil drain valve is located under the hydraulic tank.
6. Remove the hydraulic tank access cover that is Illustration 309

g00687274
located under the upper structure. This will allow
(5) Pipe Nipple
access to the drain valve. (6) Hose
(7) Drain plug
8. Replace plug (4) with a 3B-7271 Pipe Nipple (5)

and hose (6).
9. Loosen drain plug (7) in order to drain the oil.
10. Drain the oil into a suitable container.
11. After the oil has been drained, tighten drain plug
(7) to a torque of 110 ± 15 N·m (81 ± 11 lb ft).
12. Remove Pipe Nipple (5) and hose (6).

180 SEBU8371
Maintenance Section
13. Clean plug (4) and install the plug. Tighten the
plug to a torque of 75 ± 5 N·m (55 ± 48 lb ft).

machine.
15. Clean the pump, the hydraulic lines, and the

hydraulic tank.
g01121224
Illustration 311
g01121218 (8) Bolts
Illustration 310 (9) Washers
(10) Cover
16. Remove the plug from the tube. Allow the oil to (11) Spring
drain into a container. (12) Screen
Note: Dispose of used filters and used fluids 19. Remove bolts (8), washers (9) and cover (10).
Note: Dispose of used filters and used fluids
17. Inspect the O-ring. Replace the O-ring if wear or according to local regulations.
damage is evident.
Note: Do not allow spring (11) to fall back into the
18. Clean the plug. Install the plug and the O-ring into tank.
the drain port.
20. Remove spring (11) and screen (12).

21. Wash the screen in a clean nonflammable solvent.

Allow the screen to dry. Inspect the screen.
Replace the screen, if the screen is damaged.
SEBU8371 181
Maintenance Section
g00687278 g01121430
(13) O-ring seal (15) Drain hose
(14) O-ring seal (16) Connector
(17) Seal
(18) Negative flow control hose
22. Remove O-ring seal (13) from the screen.
23. Inspect O-ring seals (13) and (14). Replace the Note: Make no attempt to start the engine until the
O-ring seals if wear or damage is evident. pump has been filled with hydraulic oil. Serious
damage to the hydraulic components can result.
24. Install O-ring seal (13) on screen (12).
28. When the hydraulic oil has been replaced, the air
25. Install screen (12) and spring (11). Then install must be removed from the hydraulic oil system.
cover (10), washers (9), and bolts (8). To remove the air from the hydraulic oil system,
follow Step 28.a through Step 28.g.
Note: Make sure that the O-ring seals and the spring
are properly positioned during installation. a. While the engine is stopped, remove drain
hose (15), connector (16) and seal (17) from
26. Fill the hydraulic system oil tank. Refer to the top of the pump. Add hydraulic oil through
Operation and Maintenance Manual, “Capacities the opening.
(Refill)”.
b. Check the condition of seal (17). If the seal is
damaged, replace the seal.
c. After the pump has been filled with oil, install

drain hose (15), connector (16) and seal (17) to
the original locations.
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).

g01121239
Illustration 313
g. Stop the engine. Slowly lower the boom until
27. Inspect the O-ring seal on the filler plug for the bucket is on the ground. This pressurizes
damage. Replace the O-ring, if necessary. Clean the hydraulic tank.
the filler plug. Install the filler plug.
182 SEBU8371
Maintenance Section
Hydraulic System Oil Filter (Case Drain) - Replace
i02581934
Hydraulic System Oil Filter

(Case Drain) - Replace
SMCS Code: 5068-510; 5091-510

contact skin.
g01121273
Illustration 315
(19) Fitting
h. Slowly loosen fitting (19) until the hydraulic oil

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

speed for five minutes.
g00101435
Illustration 317

bucket to the ground so that the stick is vertical.
2. Move 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
g00101435
pressure in the pilot lines.
Illustration 316
5. Turn the engine start switch to the OFF position
30. Operate the joysticks in order to circulate the and return the lever for the hydraulic lockout
hydraulic oil. Lower the bucket to the ground so control to the LOCKED position.
that the stick is vertical to the ground. Stop the
engine.
31. Check the hydraulic oil level.
Reference: For the correct procedure, refer to

Operation and Maintenance Manual, “Hydraulic
System Oil Level - Check”.
33. Close the engine hood and latch the engine hood.
g01208340
Illustration 318
SEBU8371 183
Maintenance Section
Hydraulic System Oil Filter (Case Drain) - Replace
6. Slowly loosen the fill/vent plug on top of the

hydraulic tank in order to relieve the internal
pressure of the hydraulic tank.
7. After the pressure is relieved, tighten the fill/vent

plug.
g00101502
Illustration 321
12. Coat the seal of a new case drain filter with clean
hydraulic oil.

g00101497
Illustration 319
Instructions for the installation of the filter are
8. Open the access door on the right side of the printed on the side of each Caterpillar spin-on
machine. filter. For non-Caterpillar filters, refer to the
installation instructions that are provided by the
supplier of the filter.
14. Start the engine and operate the machine slowly

for 10 to 15 minutes. Move each cylinder evenly
through several cycles.
g01121031
Illustration 320
The case drain filter is located near the pilot oil filter.
9. Clean the area in order to keep dirt out of the filter

base.
g00101508
Note: Refer to Operation and Maintenance Manual, Illustration 322
containing fluid spillage. 15. Return the machine to the position that is shown
in Illustration 322. Check the machine for oil leaks.
10. Remove the used case drain filter from the filter
base. 16. Stop the engine.
Note: Used filters should always be disposed of 17. Check the hydraulic oil level.
11. Clean the filter base. Operation and Maintenance Manual, “Hydraulic

184 SEBU8371
Maintenance Section
Hydraulic System Oil Filter (Pilot) - Replace
i02581929 6. Slowly loosen the fill/vent plug on top of the

hydraulic tank in order to relieve the internal
Hydraulic System Oil Filter pressure of the hydraulic tank.
(Pilot) - Replace 7. After the pressure is relieved, tighten the fill/vent
SMCS Code: 5068-510; 5068-510-PS; 5092-510 plug.

contact skin.
g00101497
Illustration 325

machine.
g00101435
Illustration 323

2. Move 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 g01121062
Illustration 326
pressure in the pilot lines.
5. Turn the engine start switch to the OFF position 9. Clean the area in order to keep dirt out of the filter
and return the lever for the hydraulic lockout base.
control to the LOCKED position.
10. Remove the used pilot filter element from the

filter base.
Note: Used filters should always be disposed of

11. Clean the filter base.
g01208340
Illustration 324
SEBU8371 185
Maintenance Section
Hydraulic System Oil Filter (Return) - Replace
Note: If the message display shows that the hydraulic

return filter is plugged, turn off the machine. After you
make sure that the warning has disappeared, start
the machine and run the machine on level ground for
approximately 10 minutes. If the warning still appears
in the message display, inspect the filter and replace
the filter, if necessary.
g00101502
Illustration 327
12. Coat the seal of a new pilot filter with clean

hydraulic oil.
Instructions for the installation of the filter are Illustration 328

g01220269
printed on the side of each Caterpillar spin-on
filter. For non-Caterpillar filters, refer to the 1. Loosen the fill/vent plug in order to relieve the
installation instructions that are provided by the hydraulic tank pressure. Tighten the fill/vent plug
supplier of the filter. after the hydraulic tank pressure is relieved.
14. Check the hydraulic oil level. Note: The return filter cartridge is located on the side
of the hydraulic tank.
Operation and Maintenance Manual, “Hydraulic 2. Remove the filter cartridge. Perform Step 2.a
System Oil Level - Check”. through Step 2.f in order to remove the filter
cartridge.
i02580552
Hydraulic System Oil Filter

(Return) - Replace
SMCS Code: 5068-510-RJ

contact skin.
g00102211
Illustration 329
(1) Bolts
The return filter is a cartridge type filter. The amount (2) Washers
of foreign material that enters the hydraulic system is (3) Cover
reduced when the filter element is replaced. (4) Plug
(5) Filter cartridge
Two different filters are available for the return filter.
One filter is used for standard applications such as a. Remove bolts (1), washers (2), and cover (3).
digging and normal use of a hammer. The second
filter is used for an application such as demolishing a Note: Refer to Operation and Maintenance Manual,
ceiling in a tunnel with a hammer. “General Hazard Information” for information on
186 SEBU8371
Maintenance Section
b. Remove plug (4) in order to release the

pressure in filter cartridge (5).
Note: When plug (4) is removed the oil level in the

return filter drops to the level of the hydraulic tank.
g00102219
Illustration 332
(7) O-ring
e. Inspect the cover and O-ring (7). If either part

is damaged, replace the part.
g00102212
Illustration 330
(5) Filter cartridge f. Inspect the filter cartridge for debris and
(6) Filter case for damage. If necessary, replace the filter
(A) Guide cartridge.
c. Pull up the handle at the top of filter cartridge 3. Remove the filter element. Perform Step 3.a
(5) until the filter cartridge contacts guide (A) through Step 3.f in order to remove the filter
on filter case (6). element.
g00102214 g00104507
(4) Plug
d. Turn the filter cartridge counterclockwise by (8) Plate
180 degrees in order to align the projection of (18) O-ring
the filter cartridge with the notch of the filter
case. Pull out the filter cartridge. a. Make sure that plug (4) is removed. Make sure
that all of O-ring (18) is removed from plate (8).
SEBU8371 187
Maintenance Section
g00918893 g00104511
(8) Plate (13) Slide plate
(9) Spiral retaining ring (14) Pads
(15) Screws
(19) Port
b. Remove spiral retaining ring (9).
a. Turn shell (10) upside-down.
b. Remove screws (15).
c. Remove Pads (14) from slide plate (13).
d. Wash the following parts in a clean

nonflammable solvent: plug (4), plate (8), spiral
retaining ring (9), shell (10), and Pads (14). Dry
the parts.
5. Install the filter elements. Perform Step 5.a through

Step 5.k in order to install the filter elements.
Illustration 335
g00104510 Note: Consult a Caterpillar dealer for the Service Kit
that is needed to install the filter element and the
(8) Plate
(10) Shell filter cartridge.
(11) O-ring
(12) Filter element a. Apply spray type oil to the inside of shell (10) in
order to prevent rust.
c. Hold the filter cartridge with one hand. Grasp
the grip of plate (8) with your other hand. Lift b. Apply grease to a new O-ring (11).
plate (8) in order to separate plate (8) from the
filter cartridge. c. Plate (8) will contact the inside of shell (10).
Apply grease to this point.
d. Remove O-ring (11) from plate (8).
d. Apply grease to O-rings inside ports (19) at the
e. Lift filter element (12) from shell (10). bottom of shell (10).
f. Pour the remaining oil into a suitable container. e. Install new Pads (14). Tighten the screws to a
torque of 0.4 N·m (3.5 lb in).
Note: Dispose of used oil according to local
regulations. f. Apply spray type oil into the clearance between
shell (10) and slide plate (13).
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.
188 SEBU8371
Maintenance Section
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.
g00104512
Illustration 337
(8) Plate
(10) Shell
(16) Boss
(17) Notch
g00102221
Illustration 339
g. Turn over shell (10). Apply grease to the two
(E) Slide plate
O-rings on new element (12). Install element (D) Port
(12) into shell (10).
b. Check that ports (D) of the filter cartridge are
h. Move boss (16) in alignment with notch (17). fully closed.
Install plate (8) into shell (10).
Note: The filter cartridge cannot be installed unless
i. Install spiral retaining ring (9) into the groove the ports are fully closed. If the ports are open, rotate
in shell (10). slide plate (E) counterclockwise to the stopper in
order to fully close the ports.
j. Apply grease to new O-ring (18). Install O-ring
(18) on plug (4).
k. Install plug (4) into plate (8).
6. Install the filter cartridge. Perform Step 6.a through

Step 6.e in order to install the filter cartridge.
g00102222
Illustration 340
(F) O-rings
c. Check that O-rings (F) have been installed and

that oil has been applied to O-rings (F).
g00102220
Illustration 338
(B) Port
(C) Slide plate
a. Check that ports (B) at the bottom of the filter

case are closed.
SEBU8371 189
Maintenance Section
Hydraulic System Oil Level - Check
g00102225 g00102817
(1) Bolts The hydraulic oil tank is on the right side of the machine.
d. Install the filter cartridge into the filter case. 1. Park the machine on level ground. Lower the
Turn the filter cartridge clockwise by 180 bucket to the ground with the stick in a vertical
degrees and push down the filter cartridge position, as shown.
when the filter cartridge contacts guide (A).
e. Install plug (4), cover (3), washers (2), and bolts

(1). Tighten bolts (1) to a torque of 29 ± 5 N·m
(22 ± 4 lb ft).
7. Check the hydraulic system oil level.

Operation and Maintenance Manual, “Hydraulic
i02581923
Hydraulic System Oil Level - Illustration 343

g00102818
Check
SMCS Code: 5050-535 machine.

contact skin.
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.
g01121278
Illustration 344
(A) High temperature range
(B) Low temperature range
190 SEBU8371
Maintenance Section
Hydraulic System Oil Sample - Obtain
3. For a cold machine, maintain the hydraulic oil level i01874371

in the low temperature range (B). For a machine
that is at normal operating temperature, maintain Hydraulic System Oil Sample
the hydraulic oil level in the high temperature
range (A).
- Obtain
SMCS Code: 5050-008-OC; 5095-008; 5095-SM;
4. Close the access door. 7542-008; 7542
g01208340
Illustration 345 g00684914
Illustration 346
Note: Refer to Operation and Maintenance Manual, The hydraulic oil sampling valve is near the pilot filter.
“General Hazard Information” for information that Obtain a sample of the hydraulic oil from the hydraulic
pertains to Containing Fluid Spillage. oil sampling valve that is located on the hydraulic
oil filter housing. Refer to Special Publication,
Note: Perform Step 5 through Step 7 if the oil level SEBU6250, “S·O·S Oil Analysis” for information that
is low. pertains to obtaining a sample of the hydraulic oil.
Refer to Special Publication, PEHP6001, “How To
5. Slowly loosen the fill/vent plug in order to relieve Take A Good Oil Sample” for more information about
any pressure. Add oil, if necessary. See Operation obtaining a sample of the hydraulic oil.
and Maintenance, “Lubricant Viscosities”.
6. Check the O-ring seal of the fill/vent plug. Replace i02581915

the O-ring seal if the O-ring seal is damaged.
Hydraulic Tank Screen - Clean
7. Clean the fill/vent plug and install the fill/vent plug.
SMCS Code: 5056-070-Z3

contact skin.
SEBU8371 191
Maintenance Section
Hydraulic Tank Screen - Clean
4. Clean the area thoroughly in order to keep dirt out

of the screen cover. Clean the area thoroughly in
order to keep dirt out of the fill/vent plug.
5. Relieve the internal pressure from the hydraulic

tank by loosening the fill/vent plug. After the
pressure is relieved, remove the fill/vent plug.
g00101435
Illustration 347

2. Unlatch the engine hood and raise the engine

hood.
g01121280
Illustration 350
(4) Bolts
(5) Washers
(6) Cover
(7) Spring
(8) Screen
6. Remove bolts (4), washers (5) and cover (6).

g01121186
Illustration 348
Note: Do not allow spring (7) to fall into the tank.
(1) Bolts
(2) Washers
(3) Cover 7. Remove spring (7) and screen (8).
3. Remove bolts (1), washers (2) and cover (3) from Note: Refer to Operation and Maintenance, “General
the top of the hydraulic tank. Hazard Information” for information on containing
fluid spillage.
8. Wash the screen in a clean nonflammable solvent.

Allow the screen to dry. Inspect the screen.
Replace the screen, if the screen is damaged.
g01121188
Illustration 349
192 SEBU8371
Maintenance Section
Indicators and Gauges - Test
1. Look for broken lenses on the gauges, broken

indicator lights, broken switches, and other broken
components in the cab.
2. Start the engine.
3. Look for inoperative gauges.
4. Turn on all machine lights. Check for proper

operation.
5. Move the machine forward. Release the travel

levers and the travel pedals. The machine should
stop.
g00691204
Illustration 351 6. Stop the engine.
(9) O-ring seal
(10) O-ring seal 7. Make any repairs that are required before
operating the machine.
9. Remove O-ring seal (9) from screen (12).
10. Inspect O-ring seals (9) and (10). Replace the i02106227
O-ring seals if wear or damage is evident.
Oil Filter - Inspect
11. Install O-ring seal (9) on screen (12).
SMCS Code: 1308-507; 5068-507
12. Install screen (8) and spring (7). Then install
cover (6), washers (5), and bolts (4). Inspect a Used Filter for Debris
Note: Make sure that the O-ring seals and the spring
are properly positioned during installation.
13. Inspect the O-ring seal on the filler plug for

damage. Replace the O-ring, if necessary. Clean
the filler plug. Install the filler plug.
14. Install cover (3) with bolts (1) and washers (2).
15. Close the engine hood and latch the engine hood.
i02116248
Indicators and Gauges - Test g00100013

Illustration 353
SMCS Code: 7450-081; 7490-081 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.
Ferrous metals can indicate wear on steel parts and

on cast iron parts.
g01077750
Illustration 352
SEBU8371 193
Maintenance Section
Quick Coupler - Lubricate
Nonferrous metals can indicate wear on the i02332977

aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings. Radiator Core - Clean
Small amounts of debris may be found in the filter SMCS Code: 1353-070
element. This could be caused by friction and by
normal wear. Consult your Caterpillar dealer in order 1. Open the rear access door on the left side of the
to arrange for further analysis if an excessive amount machine.
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.
i02461929
Quick Coupler - Lubricate

(If Equipped)
g01164503
Illustration 355
SMCS Code: 6129-086
2. Lift latch (1) in order to release the latch.
Note: Caterpillar recommends the use of
5% molybdenum grease. Refer to Special
Publication, SEBU6250, “Caterpillar Machine 3. Swing the hydraulic oil cooler outward.
Fluids Recommendations” for more information on
molybdenum grease.
g00104878
Illustration 354
Typical Example
g01164506
Illustration 356
Apply lubricant through the four fittings on the quick
coupler. The quick coupler has two fittings on each 4. Remove four pins (3).
side.
5. Remove screens (2) and (4).
Note: Do not lubricate the wedge and the wear
plates. Friction is needed in order to hold the wedge 6. Check all of the core fins for debris.
in place during backfilling.
7. Remove dust and debris from all of the core fins
and from the screens.
194 SEBU8371
Maintenance Section
Receiver Dryer (Refrigerant) - Replace
Compressed air is preferred, but high pressure

water or steam can be used to remove dust and NOTICE
general debris from a core. If the refrigerant system has been open to the outside
air (without being plugged) for more than 30 minutes,
See Special Publication, SEBD0518, “Know Your the receiver-dryer must be replaced. Moisture will en-
Cooling System” for more detailed information ter an open refrigerant system and cause corrosion
about cleaning core fins. which will lead to component failure.
8. Install screens (2) and (4) with pins (3).

Refer to Service Manual, SENR5664, “Air
9. Close and latch the hydraulic oil cooler. Conditioning and Heating System with R-134a
Refrigerant for All Caterpillar Machines” for the proper
10. Close the rear access door on the left side of the procedure to change the receiver-dryer assembly
machine. 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 357
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.
SEBU8371 195
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 359
The swing bearing is located under the base of the

boom.
g01152685
Illustration 358
(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 360
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.
196 SEBU8371
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 362
g00687983
Illustration 364
“General Hazard Information” for information that 4. Remove dipstick (4).
pertains to Containing Fluid Spillage.
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

SEBU8371 197
Maintenance Section
Swing Drive Oil Level - Check
i02582101
Swing Drive Oil Level - Check

SMCS Code: 5459-535-FLV

contact skin.
g01049757
Illustration 367

“General Hazard Information” for information that
pertains to Containing Fluid Spillage.
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 365 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

contact skin.
g00684917
Illustration 366
1. Remove the dipstick.
g00684917
Illustration 368
198 SEBU8371
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, “S·O·S 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 370
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 371
(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 369 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.
SEBU8371 199
Maintenance Section
Track Adjustment - Adjust
i02255665

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 372
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 373
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 374
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.
200 SEBU8371
Maintenance Section
Tightening the Track
g00101752
Illustration 375
g01091134
Illustration 377
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
g00270405
Illustration 376
The track adjuster is located on the track frame. g01091134
Illustration 378
(1) Grease fitting
(2) Relief valve
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 N·m (25 ± 4 lb ft)

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

equalize the pressure.
SEBU8371 201
Maintenance Section
Track Adjustment - Inspect
4. Check the amount of sag. Adjust the track, as

needed.
If the correct adjustment cannot be achieved, consult

your Caterpillar Dealer.
i01590290
Track Adjustment - Inspect

SMCS Code: 4170-040
g00560313
Illustration 380
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.
5. Use the travel levers and the travel pedals to

move the machine backward. The travel alarm
Illustration 379
g00824541 should sound.
Check the track adjustment. Check the track for wear

and for excessive dirt buildup.
If the track appears to be too tight or too loose,

refer to Operation and Maintenance Manual, “Track
Adjustment - Adjust”.
i02232929
Travel Alarm - Test

(If Equipped)
SMCS Code: 7429-081 Illustration 381
g01126167
You must move the machine in order to test the travel 6. Push the alarm cancel switch. The travel alarm
alarm. should shut off.
1. Start the engine. Move the hydraulic lockout 7. Stop the machine. Lower the work tool to the
control to the UNLOCKED position. ground. Move the Hydraulic lockout control to the
LOCKED position. Stop the engine.
2. Raise the work tool in order to avoid any obstacles.
Make sure that there is adequate overhead
clearance.
202 SEBU8371
Maintenance Section
Undercarriage - Check
i00059532
Undercarriage - Check
SMCS Code: 4150-535
g00688996
Illustration 383
2. Remove the filler cap.
g00101898
3. Fill the window washer reservoir with washer fluid
Illustration 382 through the filler opening.
1. Check the carrier rollers, the track rollers, and the 4. Install the filler cap.
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 i01258249
and loose mounting bolts.
Window Wiper -
3. Listen for any abnormal noises while you are Inspect/Replace
moving slowly in an open area.
SMCS Code: 7305-040; 7305-510
4. If abnormal wear exists or abnormal noises or
leaks are found, consult your Caterpillar dealer. Inspect the condition of the wiper blades. Replace
the wiper blades if the wiper blades are worn or
damaged or if streaking occurs.
i01458697
Window Washer Reservoir - i01077829

Fill Windows - Clean
SMCS Code: 7306-544-KE
SMCS Code: 7310-070; 7340-070
NOTICE Use commercially available window cleaning
When operating in freezing temperatures, use solutions in order to clean the windows. Clean the
Caterpillar or any commercially available nonfreezing outside of the windows from the ground, unless
window washer solvent. handholds are available.
1. Open the access door on the left side of the

machine.
SEBU8371 203
Maintenance Section
Windows - Clean
g00566124
Illustration 384
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.

320D Excavator-Maintenance Intervals

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Excerpted from Operation & Maintenance Manual (SEBU8371-00-01)

i02768213 Every 10 Service Hours or Daily

Every 500 Service Hours of Partial Hammer

Every 600 Service Hours of Continuous

Every 1000 Service Hours or 6 Months

Every 1000 Service Hours of Partial Hammer

Every 1500 Service Hours

Every 2000 Service Hours or 1 Year

Air Conditioner/Cab Heater Battery - Recycle

Battery Hold-Down - Tighten

Tighten the hold-downs for the battery in order to

Battery or Battery Cable -

1. Slide the operator seat forward.

8. Connect the positive battery cable of the battery.

9. Connect the negative battery cable of the battery.

10. Install the key and turn the battery disconnect

2. Apply approximately 98 N (22 lb) force midway

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

7. If a new belt is installed, run the engine at i01933858

Apply lubricant through all fittings after operation

Wipe all fittings before you apply lubricant.

1. Apply approximately 100 N (22 lb) force midway

4. When the adjustment is correct, tighten nut (4) to

5. Check the deflection again.

Note: If a new belt is installed, check the belt

6. Close the engine hood.

2. The fittings are at the base of the boom. The

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

Two shims of different thickness are used at location

Bucket Linkage - Lubricate

Note: Caterpillar recommends the use of 5%

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

3. Place the hydraulic lockout control in the LOCKED g00682908

Block the bucket before changing bucket tips or

Bucket Tips Removal Procedure

1. The retainer can be removed from the top of the

• Use a hammer and a punch in order to drive

• Use a pin removal tool. Follow step 1.a through

Note: Carefully follow all safety instructions that are

a. Use a hammer and the short punch of the pin

1. Clean the adapter, if necessary.

2. Install the new bucket tip or the rotated bucket tip

4. The retainer is properly seated if the retainer can

Side Cutters (If Equipped)

• Use a pin removal tool. Follow step 3.a through

a. Use a hammer in order to drive the retainer

Note: Some side cutters may be rotated for additional

3. Install the side cutter.

Note: Certain bolts may require thread compound.

4. Hand tighten the bolts.

1. Hit pin (11) from the retainer side of the bucket

Side Protectors (If Equipped)

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