Maintenance Intervals: Operation and Maintenance Manual Excerpt

MAINTENANCE INTERVALS
Operation and Maintenance

Manual Excerpt
® ®
© 2010 Caterpillar
All Rights Reserved
SEBU7162-01
February 2001
Operation and
Maintenance
Manual
318B Excavator
3LR1-Up (Machine)
7KZ1-Up (Machine)
104
Maintenance Section
Maintenance Interval Schedule
i01486157 Every 50 Service Hours or Weekly

Maintenance Interval Schedule Boom, Stick and Bucket Linkage - Lubricate ...... 108
SMCS Code: 7000 Initial 100 Service Hours

Note: All safety information, warnings, and Engine Oil and Filter - Change ........................... 122
instructions must be read and understood before Fuel System Filter - Replace .............................. 125
you perform any operation or any maintenance Fuel System Priming Pump - Operate ................ 126
procedure.
Every 100 Service Hours of Continuous
Before each consecutive interval is performed, all Hammer Use
of the maintenance requirements from the previous
interval must also be performed. Hydraulic System Oil Filter - Replace ................. 133
When Required Initial 250 Service Hours

Air Conditioner/Cab Heater Filter - Inspect/ Engine Valve Lash - Check ................................. 124
Replace ............................................................. 107 Final Drive Oil - Change ..................................... 124
Battery - Recycle ................................................ 107 Hydraulic System Oil Filter - Replace ................. 133
Battery, Battery Cable or Battery Disconnect Switch - Hydraulic System Oil Return Filter - Replace ..... 136
Replace ............................................................. 107 Swing Drive Oil - Change ................................... 145
Boom Base Pins - Lubricate ............................... 108
Bucket Linkage - Inspect/Adjust .......................... 110 Every 250 Service Hours or Monthly
Bucket Tips - Inspect/Replace ............................ 111
Air Conditioner - Test .......................................... 106
Cab Air Filter - Clean/Replace ............................ 112
Condenser (Refrigerant) - Clean ........................ 113
Circuit Breakers - Reset ...................................... 113
Cooling System Hoses - Inspect ......................... 116
Engine Air Filter Primary Element -
Engine Oil and Filter - Change ........................... 122
Clean/Replace .................................................. 119
Final Drive Oil Level - Check ............................... 125
Engine Air Filter Secondary Element - Replace .. 120
Swing Bearing - Lubricate .................................. 144
Fuses - Replace .................................................. 129
Swing Drive Oil Level - Check ............................. 146
Oil Filter - Inspect ................................................ 141
V-Belts - Inspect/Adjust/Replace ........................ 150
Radiator Core - Clean ......................................... 142
Refrigerant Receiver-Dryer - Replace ................ 142
Track Adjustment - Adjust ................................... 148 Every 250 Service Hours of Partial Hammer
Windows - Clean ................................................. 153 Use (50% of Service Hours)
Window Washer Reservoir - Fill .......................... 154 Hydraulic System Oil Filter - Replace ................. 133
Window Wiper - Inspect/Replace ........................ 154
Every 10 Service Hours or Daily for First 100
Hammer Use
Hours
Hydraulic System Oil Return Filter - Replace ..... 136
Boom, Stick and Bucket Linkage - Lubricate ...... 108
Every 500 Service Hours or 3 Months
Every 10 Service Hours or Daily
Fuel System Filter - Replace .............................. 125
Cooling System Level - Check ............................ 117 Fuel System Priming Pump - Operate ................ 126
Engine Oil Level - Check .................................... 121
Fuel System Priming Pump Strainer - Clean ...... 127
Fuel System Water Separator - Drain ................. 127
Fuel Tank Cap and Strainer - Clean ................... 128
Fuel Tank Water and Sediment - Drain ............... 128 Hydraulic System Oil Filter - Replace ................. 133
Hydraulic System Oil Level - Check .................... 135
Indicators and Gauges - Test .............................. 141
Seat Belt - Inspect .............................................. 144
Every 500 Service Hours of Partial Hammer
Track Adjustment - Inspect .................................. 149 Use (50% of Service Hours)
Travel Alarm - Test .............................................. 149 Hydraulic System Oil Return Filter - Replace ..... 136
Undercarriage - Check ........................................ 150
Walk-Around Inspection ...................................... 152
Hammer Use
Every 10 Service Hours or Daily for Machines
Used in Severe Applications Hydraulic System Oil - Change ........................... 130
Boom, Stick and Bucket Linkage - Lubricate ...... 108
105
Maintenance Section
Maintenance Interval Schedule
Every 1000 Service Hours or 6 Months

Battery - Clean .................................................... 107
Battery Hold-Down - Tighten .............................. 108
Engine Valve Lash - Check ................................. 124
Hydraulic System Oil Return Filter - Replace ..... 136
Swing Drive Oil - Change ................................... 145
Water Pump Bearing - Lubricate ........................ 153
Every 1000 Service Hours of Partial Hammer

Use (50% of Service Hours)
Hydraulic System Oil - Change ........................... 130
Every 2000 Service Hours or 1 Year

Final Drive Oil - Change ..................................... 124
Hydraulic System Oil - Change ........................... 130
Refrigerant Receiver-Dryer - Replace ................ 142
Swing Gear - Lubricate ....................................... 147
Every 3 Years
Seat Belt - Replace ............................................. 144
Every 3000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .. 115
Every 6000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 114
106
Maintenance Section
Air Conditioner - Test
i01040227
Air Conditioner - Test

(If Equipped)
SMCS Code: 7320-081
Inhaling air conditioner refrigerant gas through a

lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air con-
ditioner refrigerant gas can cause bodily harm or
death. Do not smoke when servicing air condition-
ers or wherever refrigerant gas may be present.
NOTICE
When adding or replacing refrigerant, use only refrig-
erant recommended by Caterpillar. System damage
can result. g00537123
Illustration 196
3. Look at the receiver-dryer sight glass and note

the amount of refrigerant.
• In sight glass (A), only a few bubbles

are present. This indicates that there is a
satisfactory amount of refrigerant.
• In sight glass (B), many bubbles are present.

This indicates that there is a lack of refrigerant.
• In sight glass (C), small amounts of vapor are

present. This indicates that there is almost no
refrigerant.
g00537105
Illustration 194
If the condition in sight glass (B) or in sight glass
1. Start the engine and turn the engine speed dial (C) is noticed, consult your authorized Caterpillar
to the MEDIUM SPEED position. dealer for recharging.
Operation of the air conditioner without correct

amounts of refrigerant could cause failure of the
compressor.
The air conditioner should be kept ready for

operation year-round. Operate the air conditioner
for a few minutes during the week in order to
rotate the compressor. This prevents the leakage
of refrigerant. The leakage is caused by a dry
seal on the compressor.
4. Close the access door.
g00102191
Illustration 195
2. Open the access door on the left side of the

machine.
107
Maintenance Section
Air Conditioner/Cab Heater Filter - Inspect/Replace
i00062183 i00934864
Air Conditioner/Cab Heater Battery - Clean

Filter - Inspect/Replace SMCS Code: 1401-070
SMCS Code: 7309-040; 7309-510
Clean the battery surface with a clean cloth. Keep
the terminals clean and keep the terminals coated
NOTICE with petroleum jelly. Install the post cover after you
An air filter element plugged with dust will result in de- coat the terminal post with petroleum jelly.
creased performance and service life to the air condi-
tioner or cab heater (if equipped).
i00059329
To prevent decreased performance, clean the air filter
element, as required.
Battery - Recycle
SMCS Code: 1401-561
Always recycle a battery. Never discard a battery.
Always return used batteries to one of the following

locations:
• A battery supplier
• An authorized battery collection facility
• Recycling facility
i00877830
Battery, Battery Cable or

Battery Disconnect Switch -
Replace
SMCS Code: 1401-510; 1402-510; 1402-510
g00103068
Illustration 197
The air conditioner filter is on the lower left side of

the cab.
Personal injury can result from battery fumes or
1. To remove the element, slide the element straight explosion.
up.
Batteries give off flammable fumes that can ex-
2. Refer to Operation and Maintenance Manual, plode. Electrolyte is an acid and can cause per-
“General Hazard Information” before using sonal injury if it contacts the skin or eyes.
pressure air to clean the air filter element.
Prevent sparks near the batteries. Sparks could
3. Clean the filter element with a maximum of cause vapors to explode. Do not allow jumper ca-
200 kPa (30 psi) pressure air. ble ends to contact each other or the engine. Im-
proper jumper cable connections can cause an ex-
4. After you clean the filter element, inspect the plosion.
filter element. If the filter element is damaged or
badly contaminated, use a new filter element. Always wear protective glasses when working
Make sure that the filter element is dry. with batteries.
1. Turn the engine start switch key to the OFF

position. Turn all of the switches to the OFF
position.
108
Maintenance Section
Battery Hold-Down - Tighten
2. Turn the battery disconnect switch to the OFF 1. Park the machine on a level surface and lower
position. Remove the key. the bucket to the ground.
3. Disconnect the negative battery cable at the

battery.
4. Disconnect the positive battery cable at the

battery.
5. Disconnect the battery cables at the battery

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

disconnect switch.
g00103842
Illustration 199
8. Connect the positive battery cable of the battery.
2. Vent plug (1) and fitting (2) are on the base of
9. Connect the negative battery cable of the battery. the boom. Remove vent plug (1). Apply lubricant
through fitting (2) until lubricant comes out of the
10. Install the key and turn the battery disconnect plug hole.
switch to the ON position.
3. Install vent plug (1).
i00934872
i01502704
Battery Hold-Down - Tighten
Boom, Stick and Bucket
SMCS Code: 7257
Linkage - Lubricate
Tighten the hold-downs for the battery in order to
SMCS Code: 6501-086; 6502-086; 6513-086
prevent the batteries from moving during machine
operation.
Note: Caterpillar recommends the use of 5P-0960
Molybdenum Grease for lubricating the boom,
i00821394 stick and bucket linkage. Refer to Operation and
Maintenance Manual, SEBU6250, “Lubricating
Boom Base Pins - Lubricate Grease” for more information on molybdenum
grease.
SMCS Code: 6501-086
Service a new machine after Every 10 Service
When the boom pin is replaced, lubricate the new Hours only within the initial 100 service hours.
boom pin.
After the initial 100 service hours of operation,
service the boom, the stick, and the bucket control
linkage after Every 50 Service Hours.
Note: If the machine is operated under severe

conditions that might cause abrasive material to
enter the cylinder bearings or if the hydraulic
hammer is used, service the boom, the stick, and
the bucket control linkage after Every 10 Service
Hours.
g00101281
Illustration 198
109
Maintenance Section
Boom, Stick and Bucket Linkage - Lubricate
a. Raise the implement until the implement is

suspended above the ground.
b. Apply lubricant through fittings (1), (2), (3),

and (4).
c. Lower the implement to the ground.
d. Apply a slight downward pressure on the

implement.
e. Apply lubricant through fittings (1), (2), (3),

and (4).
g00102057 4. To lubricate the head end of the stick cylinder,

Illustration 200 apply lubricant through fitting (5). This fitting is
located at the base of the boom.
1. Wipe all fittings before you apply lubricant.
g00101661
Illustration 203
g00287575
Illustration 201
5. Apply lubricant through fittings (6), (7) and (9).
2. Apply lubricant through the fitting at the base These fittings are located on the link.
of each boom cylinder.
6. Apply lubricant through fitting (8). This fitting is
located on the rod end of the bucket cylinder.
7. Apply lubricant through fitting (10). This fitting

is located on the stick.
8. Apply lubricant through fittings (11) and (12).

These fittings are located on the power link.
g00287577
Illustration 202
3. Fittings (1) and (2) lubricate the lower boom

bearings. Fittings (3) and (4) lubricate the rod
end of the boom cylinders. These fittings are
located at the base of the boom.
Use Steps 3.a through 3.e to ensure proper

lubrication of the lower boom bearings and the g00287584
Illustration 204
rod end of the boom cylinders.
110
Maintenance Section
Bucket Linkage - Inspect/Adjust
9. Apply lubricant through fitting (13). Fitting (13) is

located at the junction of the boom and the stick.
g00101687
Illustration 206
(1) No gap. (2) Stick boss. (3) Bucket clearance. (4) Shims. (5)
g00287585 Pin. (6) Plate. (7) Bolts. (8) Washers. (9) Location. (10) Flange.
Illustration 205
(11) Bucket boss.
located on the rod end of the stick cylinder. The clearance of the bucket control linkage on
this machine can be adjusted by shimming.
11. Apply lubricant through fitting (15). Fitting (15) is If the gap between the bucket and the stick
located at the junction of the boom and the stick. becomes excessive, adjust bucket clearance (3) to
0.5 to 1 mm (0.02 to 0.04 inch).
located on the head end of the bucket cylinder. 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).
i01480517
Bucket Linkage -
Inspect/Adjust
SMCS Code: 6513-025; 6513-040
When performing this adjustment, put the hy-

draulic activation control lever in the LOCKED
position and stop the engine.
NOTICE Illustration 207

g00102146
Improperly adjusted bucket clearance could cause Area for linkage adjustment
galling on the contact surfaces of the bucket and stick,
resulting in excessive noise and/or damaged O-ring
1. Position the machine on a level surface and
seals. 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 activation control lever in the

LOCKED position and stop the engine.
4. Measure bucket clearance (3), which is the

existing total clearance.
111
Maintenance Section
Bucket Tips - Inspect/Replace
5. Determine the number of shims that need to be 1. Remove the pin from the bucket tip. The pin can
removed from shims (4) by using the following be removed by one of the following methods.
calculation:
• Use a hammer and a punch from the retainer
Subtract 0.5 mm (0.02 inch) or 1.0 mm (0.04 inch) side of the bucket to drive out the pin.
from bucket clearance (3).
• Use a Pin-Master. Follow Step 1.a through Step
6. Remove the appropriate number of shims at 1.c for the procedure.
location (9) in order to meet the above thickness.
Make sure that you use a minimum of three
0.5 mm (0.02 inch) shims. To remove the shims,
remove bolts (7), washers (8), and plate (6).
7. After the correct number of shims has been

removed and pin (5) is aligned with the pin
hole, install plate (6), washers (8), and bolts (7).
Tighten bolts (7) to a torque of 240 ± 40 N·m
(175 ± 30 lb ft).
8. After installation, make sure that bucket

clearance (3) is still correct.
i01117817 g00590670
Illustration 209
Bucket Tips - Inspect/Replace (4) Back of Pin-Master
(5) Extractor
SMCS Code: 6805-040; 6805-510
a. Place the Pin-Master on the bucket tooth.
b. Align extractor (5) with the pin.
Personal injury or death can result from bucket c. Strike the Pin-Master at the back of the tool
falling. (4) and remove the pin.
Block the bucket before changing bucket tips or

side cutters.
Bucket Tips
g00590819
Illustration 210
(6) Retainer
(7) Retaining washer
(8) Adapter
2. Clean the adapter and the pin.

g00101352
Illustration 208
(1) Usable
3. Fit retainer (6) into retaining washer (7). Install
(2) Replace this bucket tip. this assembly into the groove that is in the side
(3) Overworn of adapter (8).
Check the bucket tips for wear. If the bucket tip has
a hole, replace the bucket tip.
112
Maintenance Section
Cab Air Filter - Clean/Replace
d. Slide pin holder (10) away from the pin and

rotate the tool slightly in order to align pin
setter (9) with the pin.
e. Strike the end of the tool until the pin is fully

inserted.
6. After you drive the pin, make sure that the

retainer fits snugly into the pin groove.
Side Cutters
g00101359
Illustration 211
4. Install the new bucket tip onto the adapter.
Note: The bucket tip can be rotated by 180

degrees in order to allow greater penetration or less
penetration.
5. Drive the pin through the bucket tip. The pin

can be installed by using one of the following
methods:
g00114738
Illustration 213
• From the other side of the retainer, drive the
pin through the bucket tip, the adapter, and
1. Remove the mounting bolts and the side cutters.
the retainer.
2. Clean the mounting surfaces.
• Use a Pin-Master. Follow Step 5.a through Step
5.e for the procedure.
Note: Some side cutters may be rotated for
additional wear.
3. Install the new side cutters or the rotated side

cutters.
i00061455
Cab Air Filter - Clean/Replace

SMCS Code: 7342-070; 7342-510
g00590666
Illustration 212
(4) Back of Pin-Master
(9) Pin setter
(10) Pin holder
a. Insert the pin through the bucket tooth.
b. Place the Pin-Master over the bucket tooth

and locate the pin in the hole of holder (10).
c. Strike the tool with a hammer at the back of

g00102781
the tool (4) in order to start the pin. Illustration 214
The cab air filter is behind the cab.

113
Maintenance Section
Circuit Breakers - Reset
1. Loosen two bolts (1) and remove filter cover (2)

and air filter (3). Circuit Breaker Reset – Push in the button
in order to reset the circuit breaker. If the
2. Clean the air filter with a maximum of 200 kPa electrical system is working properly, the
(30 psi) pressure air. button will remain depressed. If the button does not
remain depressed, check the appropriate electrical
3. After you clean the air filter, inspect the air filter. If circuit. Repair the electrical circuit, if necessary.
the air filter is damaged or badly contaminated,
use a new air filter. (1) Alternator Circuit .................................... 60 amp
4. Install the air filter and the filter cover. (2), (3) Accessory Circuit ............................ 30 amp
Note: Make sure that the arrow on top of the air filter (4), (5) Battery Circuit .................................. 30 amp
is facing forward.
i01041005
i00936381
Circuit Breakers - Reset Condenser (Refrigerant) -

Clean
SMCS Code: 1420-529
SMCS Code: 1805-070
NOTICE
If excessively dirty, clean condenser with a brush. To
prevent damage or bending of the fins, do not use a
stiff brush.
Repair the fins if found defective.
g00393008
Illustration 215
The circuit breakers are located inside the access

door on the left side of the machine.
g00102191
Illustration 217

machine.
g00601077
Illustration 216
114
Maintenance Section
Cooling System Coolant (ELC) - Change
g00537515 g00101813
Illustration 218 Illustration 219
Typical example
1. Open the left access door.
2. Inspect the condenser for debris. Clean the
condenser, if necessary.
3. Use clean water to wash off all dust and dirt

from the condenser.
i01502733
Cooling System Coolant (ELC)

- Change
SMCS Code: 1350-044
g00101796
Illustration 220
NOTICE
Do not change the coolant until you read and under- 2. Unlatch the engine hood and raise the engine
stand the material found in the Operation and Mainte- hood.
nance Manual, SEBU6250, “Cooling System Specifi-
cations” section. Failure to do so could result in dam-
age to the cooling systems components.
NOTICE
Mixing ELC with other products reduces the effec-
tiveness of the coolant and shortens coolant life.
Use only Caterpillar products or commercial products
that have passed the Caterpillar EC-1 specifications
for pre-mixed or concentrate coolants. Use only
Caterpillar Extender with Caterpillar ELC. Failure to
follow these recommendations could result in the
damage to cooling systems components.
g00544510
Illustration 221
If ELC cooling system contamination occurs see the
topic ELC Cooling System Contamination of this op-
3. Slowly loosen the pressure cap that is on the
eration and maintenance manual.
radiator in order to release pressure from the
cooling system.
If the coolant in the machine is changed to
Extended Life Coolant from another type of 4. Remove the pressure cap.
coolant, see Operation and Maintenance Manual,
SEBU6250, “Extended Life Coolant Cooling System
Maintenance”.
115
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
9. Start the engine. Operate the engine without

the cooling system pressure cap until the water
temperature regulator opens and the coolant
level 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 cap. If the gasket is damaged, replace
the pressure cap.
12. Install the cooling system pressure cap.
g00544378 13. Stop the engine.

Illustration 222
Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information that
pertains to containing fluid spillage.
5. Open the drain valve and allow the coolant to

drain into a suitable container. The drain valve is
under the radiator.
6. Flush the cooling system. Follow Step 6.a

through Step 6.h in order to properly flush the
cooling system.
a. Close the drain valve.

g00545226
Illustration 223
b. Fill the cooling system with clean water. (1) “FULL”
(2) “LOW”
c. Install the pressure cap.
14. Check the coolant reservoir. Maintain the coolant
d. Start the engine and run the engine until the level between “FULL” mark (1) and “LOW” mark
engine reaches operating temperature. (2).
e. Stop the engine and allow the engine to cool. 15. If additional coolant is necessary, remove the
reservoir cap and add the appropriate coolant
f. Loosen the pressure cap slowly in order to solution.
relieve any pressure in the cooling system.
16. Install the reservoir cap.
g. Open the drain valve that is underneath the
radiator and allow the coolant to drain into 17. Close the engine hood and latch the engine
a suitable container. hood. Close the left access door.
h. Flush the radiator with clean water until the
draining water is transparent. i01502740
7. Close the drain valve. Cooling System Coolant

Extender (ELC) - Add
8. Add the Extended Life Coolant. Refer to the
following topics: SMCS Code: 1352; 1353; 1395
• Operation and Maintenance Manual, When a Caterpillar Extended Life Coolant (ELC) is
SEBU6250, “Cooling System Specifications” used, an Extender must be added to the cooling
system. See Special Publication, SEBU6250,
• Operation and Maintenance Manual, “Refill “Cooling Recommendations” for all cooling system
Capacities” requirements.
116
Maintenance Section
Cooling System Hoses - Inspect
Use a 8T-5296 Coolant Conditioner Test Kit to Note: Refer to Operation and Maintenance Manual,
check the concentration of the coolant. “General Hazard Information” for information on
containing fluid spillage.
NOTICE
Mixing Extended Life Coolant (ELC) with other prod- 3. It may be necessary to drain some coolant from
ucts reduces the effectiveness of the coolant and the radiator so that Caterpillar Extender can be
shortens coolant life. Use only Caterpillar products added to the cooling system.
or commercial products that have passed the Cater-
pillar EC-1 specification for premixed or concentrate Note: Always discard drained fluids according to
coolants. Use only Caterpillar Extender with Cater- local regulations.
pillar ELC. Failure to follow these recommendations
could result in the damage to cooling systems com- 4. Add Extender to the cooling system. Refer to
ponents. the following topics for the proper amount of
Caterpillar Extender:
If ELC cooling system contamination occurs refer
to Operation and Maintenance Manual, SEBU6250, • Special Publication, SEBU6250, “Extended
“ELC Cooling System Contamination”. Life Coolant (ELC)”
This machine was factory filled with Extended Life • Operation and Maintenance Manual, “Refill
Coolant. Capacities”
5. Inspect the gasket of the cooling system

pressure cap. If the gasket is damaged, replace
the pressure cap.
6. Install the cooling system pressure cap.
7. Close the engine hood and latch the engine

hood.
i00826806
Cooling System Hoses -

Inspect
g00101428
Illustration 224
SMCS Code: 1380-040
1. Unlatch the engine hood and raise the engine
hood.
g00359072
Illustration 226
g00544510 1. Unlatch the engine hood and raise the engine

Illustration 225
hood.
2. Loosen the cooling system pressure cap slowly
in order to relieve system pressure. Remove the
pressure cap.
117
Maintenance Section
Cooling System Level - Check
e. Replace the hose clamps and tighten the

hose clamps.
f. Add the appropriate coolant solution to the

cooling system. Refer to the Operation and
Maintenance Manual, “Cooling System Level
- Check”.

hood.
i01052571

g00288149
Illustration 227
SMCS Code: 1350-535
2. Inspect all hoses for leaks due to cracking and
for softness next to the clamps. Check the hoses
for loose clamps.
3. Replace hoses that are cracked or soft and

tighten any loose clamps.
Use Steps 3.a through 3.f to replace the hoses.
g00101557
Illustration 229
1. Open the left access door.
g00288136
Illustration 228
a. Slowly loosen the cooling system pressure

cap in order to relieve system pressure.
Remove the pressure cap.

“General Hazard Information” for information on
g00545226
Illustration 230
b. Drain the coolant from the cooling system to
(A) “FULL” level
a level that is below the hose that is being (B) “LOW” level
replaced.
2. Check the coolant level of the coolant reservoir.
Note: Dispose of the drained fluids according to Maintain the coolant level between the “FULL”
local regulations. mark and the “LOW” mark. If the coolant reservoir
is empty, follow Steps 2.a through 2.i.
c. Loosen the hose clamps and disconnect the
damaged hose.
d. Replace the damaged hose with a new hose.

118
Maintenance Section
g00101561 g00102170
a. Unlatch the engine hood and raise the engine f. Inspect the condition of the gasket on the
hood. pressure cap. If the gasket is damaged,
replace the pressure cap.
g. Install the cooling system pressure cap.
h. Stop the engine.
i. Close the engine hood and latch the engine

hood.

3. If additional coolant is necessary, remove the

g00544510
reservoir cap and add the appropriate coolant
Illustration 232 solution.
b. Slowly loosen the cooling system pressure 4. Install the reservoir cap.
cap in order to relieve system pressure.
Remove the pressure cap. 5. Close the left access door.
c. Add the appropriate coolant solution to the

cooling system. Refer to the following topics:
• Special Publication, SENR6250, “Cooling

System Specifications”
• Operation and Maintenance Manual, “Refill

Capacities”
d. Start the engine. Operate the engine without

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

(0.5 inch) of the bottom of the filler pipe.
119
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
i01125704 3. Loosen the three cover latches and remove the

air cleaner cover.
Engine Air Filter Primary
Element - Clean/Replace
SMCS Code: 1054-070; 1054-510
g00101415
Illustration 237
4. Remove the primary filter element from the air

cleaner housing.
g00393008
Illustration 234
5. Clean the air cleaner cover and the inside of the
1. Open the access door on the left side of the air cleaner housing.
machine.
6. Inspect the O-ring seal on the air cleaner cover.
Replace the O-ring seal if the O-ring seal is worn
or damaged.
NOTICE
Do not clean the filter elements by bumping or tapping
them. Do not use filter elements with damaged pleats,
gaskets or seals. Engine damage can result.
Make sure the cleaned filter elements are completely

dry before installing into the filter housing. Water re-
maining in the elements can cause false indications of
contamination in Scheduled Oil Sampling test results.
g00595802 7. Clean the primary filter. Inspect the primary filter.

Illustration 235
2. Squeeze the outlet tube slightly in order to purge Primary filter elements can be cleaned with
the dirt from the outlet tube. pressure air, pressure water or a detergent
washing. When pressure water is used the
maximum pressure should not exceed 280 kPa
(40 psi).
Refer to Operation and Maintenance, “General

Hazard Information” before you use pressure air
in order to clean the primary filter element.
g00289172
Illustration 236
120
Maintenance Section
Engine Air Filter Secondary Element - Replace
• Restricted Air Filter indicator on the monitor

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

of a primary filter.
Note: The primary filter can be cleaned up to six

times. Replace the primary filter if the primary filter
has been in service for one year.
14. Close the access doors.
i00702568
Illustration 238
g00102970 Engine Air Filter Secondary
Element - Replace
8. Direct air or water along the pleats inside the
primary filter element and outside the primary SMCS Code: 1054-510
filter element.
NOTICE
The primary filter element can be washed
Always replace the secondary filter element. Never at-
in warm water and nonsudsing household
tempt to reuse the secondary filter element by clean-
detergent. Rinse inside the pleats and outside
ing the element.
the pleats. Allow the primary filter element to air
dry fully.
When the primary filter element is replaced, the sec-
ondary filter element should be replaced.
9. Inspect the primary filter element after cleaning.
Do not use a primary filter element with damaged
The secondary filter element should also be replaced
pleats, damaged gaskets or damaged seals.
if the restricted Air Filter indicator comes on after the
installation of a clean primary filter element or if the
10. Encase the clean primary filter element and
exhaust smoke is still black.
store the clean primary filter element in a clean,
dry place.
11. Install the clean primary filter.
12. Install the air cleaner cover and close the

latches securely.
g00101721
Illustration 240
1. Open the access door on the front left side of

the machine.
2. See Operation and Maintenance Manual, “Engine

Illustration 239
g00288168 Air Filter Primary Element - Clean/Replace”.
Remove the air cleaner cover from the air cleaner
Note: Install the air cleaner cover properly. The housing. Remove the primary filter element from
valve must point downward. the air cleaner housing.
13. Change the filter if any of the following conditions

occurs:
121
Maintenance Section
Engine Oil Level - Check
g00101451 g00359072
3. Remove the secondary filter element. 1. Unlatch the engine hood and raise the engine
hood.
4. Cover the air inlet opening. Clean the inside of
the air cleaner housing.
5. Remove the cover from the air inlet opening.
6. Install the new secondary filter element.
7. Install the primary filter element.
8. Install the air cleaner cover and close the latches

securely.
i00902996 g00288174
Illustration 243
Engine Oil Level - Check 2. Remove the dipstick. Wipe the oil off the dipstick
and reinsert the dipstick.
SMCS Code: 1000-535
NOTICE
Do not overfill the crankcase. Engine damage can re-
sult.
Note: This machine is equipped with a function for

checking fluid levels. However, if the machine is
on an incline or the engine has been stopped only
for a short time, the engine oil does not return to
the crankcase. The fluid level cannot be properly
checked. Park the machine on level ground and
check the oil level after the engine has been
stopped for at least 30 minutes.
g00104116
Illustration 244
Check the oil level while the engine is stopped. Do
not check the oil level while the engine is running.
3. Remove the dipstick and check the dipstick. The
oil level should be between the “H” mark and
the “L” mark.
122
Maintenance Section
Engine Oil and Filter - Change
NOTICE
Operating your engine when the oil level is above the
“H” mark could cause the crankshaft to dip into the oil.
This could lead to excessively high oil temperatures
which can reduce the lubricating characteristics of the
oil, lead to bearing damage, and could result in loss of
engine power.
g00101627
Illustration 246
1. Remove the bolts that secure the access cover.

Remove the crankcase access cover.

Containing Fluid Spillage.
g00288179
Illustration 245

4. Remove the oil filler plug in order to add oil,

if necessary. See Operation and Maintenance
Manual, “Refill Capacities”.
Note: If the oil is deteriorated or badly contaminated,

change the oil regardless of the maintenance
interval.
5. Clean the oil filler plug. Install the oil filler plug. g00288304
Illustration 247
6. Close the engine hood. Latch the engine hood. 2. Open the crankcase drain valve. Allow the oil to
drain into a suitable container.
i00931799
Note: Discard any drained fluids according to local
Engine Oil and Filter - Change regulations.
SMCS Code: 1318-510 3. Close the drain valve.
Note: If the sulfur content in the fuel is greater than 4. Install the crankcase access cover.
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.
123
Maintenance Section
Engine Oil and Filter - Change
g00101449 g00101634
The engine oil filter is located behind the right side door.
8. Apply a light coat of engine oil to the gasket of
5. Open the access door on the right side of the the new filter.
machine.
9. Install the new filter by hand. When the gasket
contacts the filter base, turn the filter by 3/4 of a
turn more. This will tighten the filter sufficiently.
g00288305
Illustration 249
6. Remove the oil filter. Refer to Operation and

g00359072
Maintenance Manual, “Oil Filter - Inspect”. Illustration 251
Discard the used oil filter properly.
7. Clean the filter housing base. Make sure that all hood.
of the former filter gasket is removed.
Note: This oil filter is a cartridge type filter. This type

of filter cannot be reused.
Note: Always discard the used filters according to

local regulations.
g00288310
Illustration 252
(1) Dipstick. (2) Oil filler plug.
124
Maintenance Section
Engine Valve Lash - Check
11. Remove oil filler plug (2). Fill the crankcase with i01041923
new oil. Refer to Operation and Maintenance
Manual, “Refill Capacities” and Operation and Final Drive Oil - Change
Maintenance Manual, “Lubricant Viscosities”.
Clean the oil filler plug and install the oil filler SMCS Code: 4050-044-FLV
plug.
NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
12. Start the engine and allow the oil to warm.

Check the engine for leaks. Stop the engine.
g00538194
Illustration 254
(1) Oil drain plug
(2) Oil level plug
1. Position one final drive so that oil drain plug (1)

is at the bottom.

g00104116 Containing Fluid Spillage.
Illustration 253
2. Remove drain plug (1) and level plug (2). Allow

13. Wait for thirty minutes in order to allow the oil
the oil to drain into a suitable container.
to drain back into the crankcase. Check the oil
level with dipstick (1). Maintain the oil between
3. Clean the plugs and inspect the O-ring seals. If
the “H” and the “L” marks on the dipstick. If
wear or damage is evident, replace the drain
necessary, add oil.
plug, the level plug, and/or the O-ring seals.
4. Install drain plug (1).
hood.
5. Fill the final drive to the bottom of the opening on
15. Close the access door on the right side of the
level plug (2). See Operation and Maintenance
machine.
Manual, “Lubricant Viscosities” and Operation
and Maintenance Manual, “Refill Capacities”.
i00074962
6. Install level plug (2).
Engine Valve Lash - Check
7. Perform Step 1 to Step 6 on the other final drive.
SMCS Code: 1105-535 Use a different container for the oil so that the oil
samples from the final drives will be separate.
In order to perform the complete procedure for the
valve lash adjustment, refer to the Service Manual. 8. Completely remove the oil that has spilled onto
surfaces.
9. Start the engine and allow the final drives to run

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

particles. If there are any chips or particles,
consult your Caterpillar dealer.
125
Maintenance Section
Final Drive Oil Level - Check
12. Properly dispose of the drained material. Obey i00825264

local regulations for the disposal of the material.
Fuel System Filter - Replace
i01042154 SMCS Code: 1261-510
Final Drive Oil Level - Check NOTICE
SMCS Code: 4050-535-FLV Turn the disconnect switch OFF or disconnect the bat-
tery when changing fuel filters.
Do not fill fuel filters with fuel before installing them.

Contaminated fuel will cause accelerated wear to fuel
systems parts.
g00538194
Illustration 255
(1) Oil drain plug
(2) Oil level plug
1. Position one final drive so that oil drain plug (1)

is at the bottom. Illustration 256
g00359072
Note: Refer to Operation and Maintenance Manual, 1. Unlatch the engine hood and raise the engine
“General Hazard Information” for information on hood.
2. Remove oil level plug (2). “General Hazard Information” for information on
3. Check the oil level. The oil should be near the
bottom of the level plug opening.
4. Add oil through the level plug opening, if

necessary.
Note: Overfilling the final drive will cause the seals

on the travel motor to allow hydraulic oil or water
to enter the final drive. This may contaminate the
final drive.
5. Clean oil level plug (2). Inspect the O-ring seal.

Replace the O-ring seal if the O-ring seal is worn
or damaged.
6. Install oil level plug (2). g00288334

Illustration 257
7. Repeat the procedure for the other final drive. 2. Remove the filter.
Note: This fuel filter is a cartridge type filter. This

type of filter cannot be reused.
Note: Always discard the used filters according to

local regulations.
126
Maintenance Section
Fuel System Priming Pump - Operate
3. Clean the filter mounting base. Make sure that all 3. When the above procedure has been performed,
of the used seal is removed. the engine will be ready to start. If the engine
does not start, prime the fuel system. For more
details, refer to the next section of this Operation
and Maintenance Manual, “Fuel System Priming
Pump - Operate”.
4. After this procedure is completed, operate the

engine at low idle for several minutes. Check the
fuel system for leaks.
i00645608
Fuel System Priming Pump -

Operate
g00102044
Illustration 258 SMCS Code: 1258
4. Coat the seal of the new filter with clean diesel After the strainer is cleaned, fill up the fuel tank and
fuel. the fuel system priming pump. Use the following
procedure. If the engine stalled due to no fuel, top
5. Install the new fuel filter by hand. When the seal up the fuel tank and the fuel system priming pump
contacts the filter mounting base, tighten the using the following procedure.
filter by an additional 3/4 turn.
6. Prime the fuel system. Refer to Operation and

Maintenance Manual, “Fuel System Priming
Pump - Operate”.

hood.
Releasing Air From Fuel System

After the fuel filter is replaced, release the air from
the fuel system. Use the following procedure.
g00288425
Illustration 260
1. Loosen air vent (1) on the fuel filter.
2. Unlock the priming pump by turning plunger (2)

counterclockwise. Pull the plunger up. Operate
the priming pump by moving plunger (2) up and
down until fuel that is free of air bubbles flows
out of air vent (1).
3. When the fuel flows free of air bubbles, lock the

priming pump. Push the plunger inward and
rotate the plunger in a clockwise motion. This
Illustration 259 g00288797 motion will lock the priming pump.
1. Place engine speed dial (1) at the low idle 4. Tighten air vent (1).
position.
Note: Lock the priming pump before the vent plug
2. Turn engine start switch (2) to the ON position is tightened. Pressure in the fuel system could make
and allow the engine to crank for ten to fifteen locking the plunger in place difficult. Wipe away
seconds. This will remove the air from the fuel any spilled fuel.
system.
127
Maintenance Section
Fuel System Priming Pump Strainer - Clean
5. After priming the fuel system, run the engine i01125750

at low idle for several minutes. Check the fuel
system for leaks. Fuel System Water Separator
- Drain
i00645969 (If Equipped)
Fuel System Priming Pump SMCS Code: 1263
Strainer - Clean
SMCS Code: 1258
Clean the strainer whenever a loss of engine power

is still apparent after changing the fuel filter.
g00393008
Illustration 262

machine.
g00288503
Illustration 261

1. Disconnect the fuel line at the fuel transfer pump.

Use a plug to stop the fuel leakage.
2. Remove bolt (1).
3. Remove screen (2) from bolt (1). Wash the

screen in a clean, nonflammable solvent. g00293673
Illustration 263
4. Install the screen into the bolt.

2. Turn the drain valve that is located at the
bottom of the primary filter/water separator
5. Install bolt (1). Remove the plug from the fuel line
counterclockwise.
and reconnect the fuel line to the fuel transfer
pump.
3. Drain the water and drain the sediment into a

suitable container.
Note: Dispose of drained fluids according to local

regulations.
4. Close the drain valve.

128
Maintenance Section
Fuel Tank Cap and Strainer - Clean
i00645598 4. Install the fuel fill screen.

Fuel Tank Cap and Strainer - 5. Put a light coating of fuel oil on the cap gasket.
Clean 6. Install the fuel cap.
SMCS Code: 1273-070-STR
i01502765
Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543
The fuel tank drain valve is located underneath the

fuel tank.
g00288393
Illustration 264
1. Remove the fuel cap and the fuel fill screen.
g00535969
Illustration 267

1. Open the drain valve by turning the valve

counterclockwise. Allow the water and the
Illustration 265 g00104238 sediment to drain into a suitable container.
2. Inspect the cap. Replace the cap if the cap is Note: Dispose of drained fluids according to local
damaged. regulations.
2. Close the drain valve by turning the valve

clockwise.
Fill the Fuel Tank

You can now add fuel to the fuel tank, if necessary.
Remove the fuel tank cap and pump fuel through
the opening.
Make sure that you lock the fuel tank cap after the
refueling is complete.
g00104239
Illustration 266
3. Wash the fuel fill screen in a clean, nonflammable

solvent and dry the fuel fill screen.
129
Maintenance Section
Fuses - Replace
i00925326
Fuses - Replace
SMCS Code: 1417-510
g00293681
Illustration 268
The fuse panel is located in the left console. Open

the access cover for fuse access.
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. Illustration 269
g00485892
NOTICE Timer Relay (1) – 15 Amp

If it is necessary to replace fuses frequently, an elec-
trical problem may exist. Cab Dome Light and Horn (2) – 5 Amp
Contact your Caterpillar dealer. Cab and Chassis Lamp (3) – 15 Amp
Engine Start Switch Key (4) – 10 Amp

To replace a fuse, use a puller that is stored in
the fuse panel. One fuse of 5 Amperes, one fuse Heater and Air Conditioner (If Equipped) (5) – 15
of 10 Amperes and one fuse of 15 Amperes are Amp
contained in the fuse panel as spare fuses.
Fan (6) – 20 Amp
The following list identifies the circuits that are
protected by each fuse. The amperage for each Refueling Pump (If Equipped) (7) – 15 Amp
fuse is included with each circuit.
Engine Controller or Pump Controller (8) – 10 Amp
Seat Heater (If Equipped) (9) – 5 Amp
Boom Light (10) – 10 Amp
Radio (If Equipped) / Switch Panel (11) – 5 Amp
AUTO Lubricator (If Equipped) (12) – 10 Amp

130
Maintenance Section
Hydraulic System Oil - Change
Auxiliary Circuit (Attachment) (13) – 10 Amp
Cigar Lighter (14) – 10 Amp
Hydraulic Lock Limit Switch or Hydraulic Solenoid

(15) – 5 Amp
Engine Governor (16) – 5 Amp
Inspection Lamp (If Equipped) (17) – 10 Amp
Lower Windshield Washer and Lower Windshield

Wiper (If Equipped) (18) – 10 Amp
Converter (19) – 10 Amp
Attachment Solenoid (20) – 10 Amp
Windshield Washer and Windshield Wiper (21) –

10 Amp
Backup (22) – 5 Amp Illustration 271

g00102825
(1) Bolts
Auxiliary Circuit (Attachment) (23) – 10 Amp (2) Washers
(3) Cover
Power Window (If Equipped) (24) – 15 Amp
2. Remove bolts (1), washers (2) and the cover (3)
Spare (25) – 5 Amp from the top of the hydraulic tank.
Spare (26) – 10 Amp
Spare (27) – 15 Amp
i01125805

SMCS Code: 5056-044
g00104289
Illustration 272
3. 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.
4. Relieve the internal pressure from the hydraulic

tank by loosening the fill/vent plug. After the
pressure is relieved, remove the fill/vent plug.
g00101435
Illustration 270
1. Park the machine on level ground. Lower the

bucket to the ground so that the stick is vertical.
131
Maintenance Section
8. Install a Swivel Hose with clear plastic tubing in

order to open the drain valve. Drain the oil into a
suitable container.
9. Remove the Swivel Hose in order to close the

drain valve.
10. Inspect the O-ring. Replace the O-ring if wear

or damage is evident.
11. Clean the drain plug. Install the drain plug.
g00101446
Illustration 273
5. The oil drain valve is located under the hydraulic

tank.
6. Remove the hydraulic tank access cover that is

located under the upper structure. This will allow
access to the drain valve.
g00101449
Illustration 276
12. Open the access door that is located on the

right side of the machine.
13. Clean the pump. Clean the hydraulic lines.

Clean the hydraulic tank.
g00104295
Illustration 274

7. Remove the oil drain valve plug.
g00101490
Illustration 277
(4) Bolt
(5) Washer
(6) Cover
(7) Spring
g00293719 (8) Screen
Illustration 275
14. Remove bolts (4), washers (5), and cover (6).

132
Maintenance Section
Note: Used filters and used fluids should always

be disposed of according to established local
regulations.
Note: Do not allow spring (7) to fall into the tank.
15. Remove spring (7) and screen (8).
Note: Refer to Operation and Maintenance, “General

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

solvent. Allow the screen to dry. Inspect the
screen. Replace the screen, if the screen is g00104296
damaged. Illustration 279
21. Remove the pressure cap.
g00101492
Illustration 278
(9) O-ring seal g00101462
(10) O-ring seal Illustration 280
17. Inspect O-ring seals (9) and (10). Replace the 22. Inspect the pressure cap. Clean the pressure
O-ring seals if wear or damage is evident. cap. Replace the pressure cap if damage is
evident.
18. Install a new screen and spring (7). Then install
cover (6), washers (5), and bolts (4). 23. Install the pressure cap.
Note: Make sure that the O-ring seals and the spring
are properly positioned during installation.
19. Fill the hydraulic system oil tank. Refer to

Operation and Maintenance Manual, “Refill
Capacities”.
20. Inspect the O-ring on the filler plug for damage.

Replace the O-ring, if necessary. Clean the filler
plug. Install the filler plug.
g00287566
Illustration 281
Note: Make no attempt to start the engine until the

pump has been filled with hydraulic oil. Serious
damage to the hydraulic components can result.
133
Maintenance Section
Hydraulic System Oil Filter - Replace
24. When the hydraulic oil has been replaced,the air

must be removed from the hydraulic oil system.
Use the following procedure to remove the air
from the hydraulic oil system.
a. While the engine is stopped, remove the

vent plug from the top of the pump. Do not
install the vent plug until the pump is filled
with hydraulic oil. After the pump is filled with
hydraulic oil, tighten the vent plug. Start the
engine. When the engine is at low idle, fully
raise the boom. Hold the boom in this position.
b. Stop the engine. Slowly lower the boom until

the bucket is on the ground. This pressurizes g00400491
the hydraulic tank. Illustration 283
(A) High Temperature Range
c. Slowly loosen the vent plug for several turns (B) Low Temperature Range
until the hydraulic oil flows out of the opening
for the vent plug. This indicates that the air 28. Maintain the oil level between the marks on
has been released from the pump. Tighten the sight gauge in the appropriate temperature
the plug. range.
25. Close the access door. i00818961
26. Start the engine. Operate the engine at idling Hydraulic System Oil Filter -
speed for five minutes.
Replace
SMCS Code: 5068-510
Replace the Pilot Filter
g00101435
Illustration 282
27. Operate the control levers in order to circulate

the hydraulic oil. Lower the bucket to the ground
so that the stick is vertical to the ground. Stop
the engine. g00101449
Illustration 284
1. Open the access door on the right side of the

machine.
134
Maintenance Section
Hydraulic System Oil Filter - Replace
Replace the Case Drain Filter
g00400487
Illustration 285
g00101449
Illustration 287
2. Clean the area in order to keep dirt out of the
filter base. 1. Open the access door on the right side of the
machine.
3. Remove the used pilot filter element from the
filter base.
Note: This element is a cartridge type filter. The

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

according to local regulations.
4. Clean the filter base.
g00400489
Illustration 288
2. Clean the area in order to keep dirt out of the

filter base.
3. Remove the used case drain filter from the filter

base.
Note: This element is a cartridge type filter. The

g00101502 element cannot be reused.
Illustration 286
Note: Used filters should always be disposed of
5. Coat the seal of a new pilot filter with clean according to local regulations.
hydraulic oil. Install the new pilot filter in the filter
base. Tighten the pilot filter hand tight. 4. Clean the filter base.
135
Maintenance Section
Hydraulic System Oil Level - Check
g00101502 g00400491
(A) High temperature range
5. Coat the seal of a new case drain filter with clean (B) Low temperature range
hydraulic oil. Install the new case drain filter in
the filter base. Tighten the case drain filter hand 11. Maintain the oil level in the low temperature
tight. range for a cold machine. Maintain the oil level
in the high temperature range for a machine that
6. Close the access door. is at a normal operating temperature.
7. Drive the machine slowly for 10 minutes to 15

minutes. Move each cylinder evenly through
several cycles.
g00103996
Illustration 292
12. Slowly loosen the filler plug in order to relieve

any pressure. Remove the filler plug in order to
g00101435
Illustration 290 add oil, if necessary.
8. Return the machine to the position that is shown 13. Clean the filler plug. Install the filler plug.
above. Check the machine for oil leaks.
9. Stop the engine.
i00818967
machine in order to access the sight gauge. Hydraulic System Oil Level -
Check
SMCS Code: 5050-535
NOTICE
Never remove the fill/vent plug from the hydraulic tank
if the oil is hot.
Air can enter the system and cause pump damage.

136
Maintenance Section
Hydraulic System Oil Return Filter - Replace
3. For a cold machine, maintain the hydraulic oil

level in the low temperature range. For a machine
that is at normal operating temperature, maintain
the hydraulic oil level in the high temperature
range.
g00102817
Illustration 293
The hydraulic oil tank is on the right side of the machine.
1. Park the machine on level ground. Lower the

bucket to the ground with the stick in a vertical
position, as shown.
g00103996
Illustration 296

5. Slowly loosen the filler plug in order to relieve

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

the O-ring seal if the O-ring seal is damaged.
7. Clean the filler plug and install the filler plug.

g00102818
Illustration 294
i00674798

machine.
Hydraulic System Oil Return
Filter - Replace
SMCS Code: 5068-510-RJ
Remove the Filter Cartridge

The return filter is a cartridge type filter. The return
filter reduces the amount of foreign material that
enters the hydraulic system when the filter element
is replaced.
g00400491
Illustration 295
(A) High temperature range
(B) Low temperature range
137
Maintenance Section
g00102209 g00102211
(1) Bolts. (2) Washers. (3) Cover. (4) Plug. (5) Filter cartridge.
Note: If the indicator for a Restricted Hydraulic
Return Filter comes on, push the reset switch at 2. Remove bolts (1), washers (2), and cover (3).
the filter case. Run the machine on level ground
for approximately 10 minutes. If the indicator still Note: Refer to Operation and Maintenance Manual,
comes on, inspect the filter and replace the filter, if “General Hazard Information” for information on
necessary. Containing Fluid Spillage.
3. Remove plug (4) in order to release the pressure

in filter cartridge (5).
g00104227
Illustration 298
1. Loosen the filler plug in order to relieve the

hydraulic tank pressure. Tighten the filler plug Illustration 300
g00102212
after the hydraulic tank pressure is relieved. (5) Filter cartridge. (6) Filter case. (A) Guide.
Note: The return filter is located behind the filler 4. Pull up the handle at the top of filter cartridge
plug. (5) until the filter cartridge contacts guide (A)
on filter case (6).
138
Maintenance Section
Remove the Filter Element
g00102214
Illustration 301
g00104507
Illustration 303
5. Turn the filter cartridge counterclockwise by 1/2 (4) Plug. (8) Plate. (18) O-ring.
turn in order to align the projection of the filter
cartridge with the notch of the filter case. Pull 1. Make sure that plug (4) is removed. Make sure
out the filter cartridge. that all of O-ring (18) is removed from plate (8).
g00102219 g00104508
(7) O-ring. (8) Plate. (9) Spiral retaining ring.
6. Inspect the cover and O-ring (7). If either part is 2. Use a flat screwdriver in order to remove spiral
damaged, replace the part. retaining ring (9).
7. Inspect the filter cartridge for debris and for
damage. If necessary, replace the filter cartridge.
g00104510
Illustration 305
(8) Plate. (10) Shell. (11) O-ring. (12) Filter element.
139
Maintenance Section
3. Hold the filter cartridge with one hand. Grasp 6. Spray oil into the clearance between shell (10)
the grip of plate (8) with your other hand. Lift and slide plate (13).
plate (8) in order to separate plate (8) from the
filter cartridge.
4. Remove O-ring (11) from plate (8).
5. Lift filter element (12) from shell (10).
6. Pour the remaining oil into a suitable container.
Clean Shell of Filter Cartridge
g00104512
Illustration 307
(8) Plate. (10) Shell. (16) Boss. (17) Notch.
7. Turn over shell (10). Apply grease to the two

O-rings on new element (12). Install element (12)
into shell (10).
8. Move boss (16) in alignment with notch (17).

Install plate (8) into shell (10).
Illustration 306
g00104511 9. Install spiral retaining ring (9) into the groove in
shell (10).
(13) Slide plate. (14) Blotter Pads. (15) Screws. (19) Port.
10. Apply grease to new O-ring (18). Install O-ring
1. Turn shell (10) upside-down. (18) on plug (4).
2. Remove screws (15).
11. Install plug (4) into plate (8).
3. Remove Blotter Pads (14) from slide plate (13).
Install the Filter Cartridge
4. Wash the following parts in a clean nonflammable
solvent: plug (4), plate (8), spiral retaining ring
(9), shell (10), and Blotter Pads (14). Dry the
parts.
Install the Filter Element

Note: Use the parts found in 137-3635 Service
Kit when installing the filter element and the filter
cartridge.
1. Spray oil to the inside of shell (10) in order to

prevent rust.
2. Apply grease to a new O-ring (11). g00102220

Illustration 308
3. Plate (8) will contact the inside of shell (10). (B) Port. (C) Slide plate.
Apply grease to this point.
1. Check that ports (B) at the bottom of the filter
4. Apply grease to O-rings inside ports (19) at the case are closed.
bottom of shell (10).
5. Install new Blotter Pads (14). Tighten the screws

to a torque of 0.4 N·m (3.5 lb in).
140
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.
g00102225
Illustration 311
(1) Bolts.
4. Install the filter cartridge into the filter case. Turn

the filter cartridge clockwise by 1/2 turn and
g00102221
Illustration 309 push down the filter cartridge when the filter
(E) Slide plate. (D) Port. cartridge contacts guide (A).
2. Check that ports (D) of the filter cartridge are 5. Install plug (4), cover (3), washers (2), and bolts
fully closed. (1). Tighten bolts (1) to a torque of 29 ± 5 N·m
(22 ± 4 lb ft).
Note: The filter cartridge cannot be installed unless
the ports are fully closed. If the ports are open,
rotate slide plate (E) counterclockwise to the
stopper in order to fully close the ports.
g00104319
Illustration 312
6. To turn off the indicator for a Restricted Hydraulic

Return Filter, push the reset switch on the filter
g00102222 case while the engine start switch is in the ON
Illustration 310
(F) O-rings. position.
3. Check that O-rings (F) have been installed and

that oil has been applied to O-rings (F).
141
Maintenance Section
Indicators and Gauges - Test
i00107754 i01479169
Indicators and Gauges - Test Oil Filter - Inspect

SMCS Code: 7450-081; 7490-081 SMCS Code: 1308-507; 5068-507
Inspect A Used Filter for Debris
g00106777
Illustration 313
1. Look for broken lenses on the gauges, broken g00100013

Illustration 314
indicator lights, broken switches, and other
broken components in the cab. The element is shown with debris.
2. Start the engine. Use a 4C-5084 Filter Cutter or a 175-7546 Oil

Filter Cutter to cut the filter element open. Spread
3. Look for inoperative gauges. apart the pleats and inspect the element for metal
and for other debris. An excessive amount of debris
4. Turn on all machine lights. Check for proper in the filter element can indicate a possible failure.
operation.
If metals are found in the filter element, a magnet
5. Move the machine forward. Release the travel can be used to differentiate between ferrous metals
levers and the travel pedals. The machine should and nonferrous metals.
stop.
Ferrous metals can indicate wear on steel parts and
6. Stop the engine. on cast iron parts.
7. Make any repairs that are required before Nonferrous metals can indicate wear on the
operating the machine. aluminum parts of the engine such as main
bearings, rod bearings, or turbocharger bearings.
Small amounts of debris may be found in the filter

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

by Caterpillar can result in severe engine damage
to engine bearings, to the crankshaft, and to other
parts. This can result in larger particles in unfiltered
oil. The particles could enter the lubricating system
and the particles could cause damage.
142
Maintenance Section
Radiator Core - Clean
i01491316 i01503128
Radiator Core - Clean Refrigerant Receiver-Dryer -

SMCS Code: 1353-070
Replace
SMCS Code: 7322-510
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.
g00287670
Illustration 315 Always use precaution when a fitting is removed.
(1) Wing bolts Slowly loosen the fitting. If the system is still under
(2) Screen pressure, release it slowly in a well ventilated area.
1. Loosen wing bolts (1) on the front of the radiator. Personal injury or death can result from inhaling
Remove screen (2) from the radiator. refrigerant through a lit cigarette.
Inhaling air conditioner refrigerant gas through a

lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air con-
ditioner refrigerant gas, can cause bodily harm or
death.
Do not smoke when servicing air conditioners or

wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to prop-

erly remove the refrigerant from the air condition-
ing system.
g00287672
Illustration 316 Replacement Procedure
2. Check the radiator fins for debris. (Receiver-Dryer with Quick
Couplers)
3. Remove dust and debris from the radiator fins
and from the screen of the radiator.
Compressed air is preferred, but high pressure

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

Cooling System” for more detailed information
about cleaning radiator fins.
4. Install screen (2) to the radiator, and tighten wing

bolts (1).
g00393008
Illustration 317
143
Maintenance Section
Refrigerant Receiver-Dryer - Replace
1. Open the access door on the left side of the Replacement Procedure
machine. The receiver-dryer is located behind
this access door.
(Receiver-Dryer without Quick
Couplers)
2. Stop the engine. Allow the air conditioning
system to remain inactive for five minutes in
order to equalize the pressure.
3. If the receiver-dryer is equipped with electrical

connections, disconnect the electrical
connections.
4. Disconnect the “IN” hose from the old

receiver-dryer. This is the hose that connects the
condenser to the receiver-dryer.
5. Connect the “IN” hose that was disconnected

in Step 4 to the “IN” coupler on the new
receiver-dryer.
g00359072
Illustration 318
6. Start the engine and operate the air conditioning
system for one minute in order to evacuate the
refrigerant from the old receiver-dryer.
Note: This procedure is performed in order to

ensure that the amount of refrigerant in the system
does not change.
7. With the air conditioning system in operation,

disconnect the “OUT” hose from the old
receiver-dryer. Disconnect the “OUT” hose at the
quick coupler. This is the hose that connects the
receiver-dryer to the heater/air conditioner unit.
8. Stop the engine. The air conditioning system g00393008

must be idle for five minutes in order to equalize Illustration 319
the pressure.
NOTICE
9. Connect the “OUT” hose that was disconnected If the refrigerant system has been open to the outside
in Step 7 to the coupler on the new receiver-dryer. air (without being plugged) for more than 30 minutes,
the receiver-dryer must be replaced. Moisture will en-
10. If any brackets were removed in order to remove ter an open refrigerant system and cause corrosion
the used receiver-dryer, install these brackets. which will lead to component failure.
11. If the receiver-dryer is equipped with electrical

1. Open the engine hood and open the rear access
connections, connect the electrical connections
door on the left side machine.
at this time.
2. Remove the refrigerant from the system. Refer to
Testing and Adjusting, “Refrigerant Recovery” for
the proper procedure.
3. Evacuate the system. Refer to Testing and

Adjusting, “Refrigerant System - Evacuate” for
the proper procedure.
144
Maintenance Section
Seat Belt - Inspect
When this machine was shipped from Caterpillar,

Inc., this machine was equipped with a seat
belt and with a seat belt installation. At the time
of installation, the seat belt and the seat belt
installation met “SAE J386 JUN85” for an industrial
machine and “SAE J386 JUN93”. Consult your
Caterpillar dealer for all replacement parts.
Regardless of appearance, replace the seat belt

after every three years of use. A date label for
determining the age of the seat belt is attached to
each seat belt.
Always check the condition of the seat belt and

g00448049 the condition of the seat belt mounting hardware
Illustration 320 before you operate the machine. If damage or wear
This is an example of a receiver-dryer that does not have quick is found, replace either the seat belt or the seat belt
couplers. mounting hardware before operating the machine.
4. Remove the receiver-dryer. Refer to Disassembly
and Assembly, “Air Conditioner Dryer - Remove i00731002
and Install” for the proper procedure.
Seat Belt - Replace
5. Install a new receiver-dryer. Refer to Disassembly
and Assembly, “Air Conditioner Dryer - Remove SMCS Code: 7327-510
and Install” for the proper procedure.
6. Charge the system with new R-134a refrigerant.

Refer to Testing and Adjusting, “Refrigerant
System - Charge” for the proper procedure.
7. Check the entire air conditioning system for

leaks.
Note: Use a 4C-2964 Electronic Leak Detector to

check for leaks.
8. Close the engine hood and close the rear access

door on the left side of the machine.
g00037721
Illustration 322
i00112638
Regardless of the appearance, replace the seat belt
Seat Belt - Inspect once during every three year interval.
SMCS Code: 7327-040

i00826873
Swing Bearing - Lubricate

SMCS Code: 7063-086
Wipe the fittings before you lubricate the swing

bearings.
g00101563
Illustration 321
145
Maintenance Section
Swing Drive Oil - Change
g00101569 g00104281
The swing bearings are under the base of the boom. Note: Refer to Operation and Maintenance Manual,
1. Remove drain plug (1). Allow the oil to drain into

a suitable container.
2. Use a clean, nonflammable solvent to clean oil

drain plug (1). Apply pipe sealant to the plug.
3. Install oil drain plug (1).
g00287576
Illustration 324
Apply lubricant through the fittings until the lubricant

overflows the bearing seals.
i00822248
Swing Drive Oil - Change

SMCS Code: 5459-044 g00287627
Illustration 327
4. Remove dipstick (2).
5. Add the specified quantity of oil through the

dipstick tube. See Operation and Maintenance
Manual, “Refill Capacities”.
g00101586
Illustration 325
The oil drain plug is under the center of the upper

structure.
146
Maintenance Section
Swing Drive Oil Level - Check
g00104248 g00287629
6. Make sure that the oil level is maintained 1. Remove the dipstick.
between the marks on dipstick (2).
7. Check the oil that has been drained for metal

chips or metal particles. Consult your Caterpillar
dealer if any metal chips or metal particles are
found.
8. Drained materials should always be disposed of

according to local regulations.
i00826799
Swing Drive Oil Level - Check

SMCS Code: 5459-535-FLV g00102725
Illustration 331

“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.
3. Insert the dipstick.
g00101622
Illustration 329
The dipstick for the swing drive oil is on the swing

drive at the rear base of the boom.
147
Maintenance Section
Swing Gear - Lubricate
i00998900
Swing Gear - Lubricate

SMCS Code: 7063-086
NOTICE
Improper lubrication can cause damage to machine
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, g00287641
thereby accelerating grease deterioration. Illustration 334
Grease deterioration can cause damage to the pinion 2. Inspect gasket (4). Replace the gasket if damage
gear of the swing drive and swing internal gear. is evident.
Not enough grease will result in poor gear lubrication. 3. Check the level of the grease. The grease should
be evenly distributed on the floor of the pan.

“Refill Capacities” for the size of the pan.
Add grease, as needed. Remove grease, as

needed. Too much grease will result in the
deterioration of the grease because of excessive
movement of the grease. Too little grease will
result in poor lubrication of the swing gear.
g00287633
Illustration 332
Remove the inspection cover that is located near

the boom base. Inspect the grease.
g00101653
Illustration 335
4. Check for contamination and for discolored

grease.
5. If the grease is contaminated or discolored with

water, change the grease. Remove plug (5) in
order to allow the water to drain. When you
reinstall plug (5), inspect O-ring seal (6). Replace
g00287635 the O-ring seal if damage is evident.
Illustration 333
1. Remove bolts (1) and washers (2). Remove

cover (3) and gasket (4).
148
Maintenance Section
Track Adjustment - Adjust
Measuring Track Tension
g00101644
Illustration 336
g00101752
Illustration 337
6. Raise the boom and turn the upper structure by
90 degrees. Lower the bucket to the ground. 1. Place a straight edge on the tracks. The straight
edge should be long enough to reach from the
7. Repeat Step 3 through Step 6 for one complete idler to the carrier roller.
revolution.
2. Measure the maximum amount of sag in the
8. Install gasket (4), cover (3), washers (2), and track. The sag is measured from the highest
bolts (1). point of the track grouser to the bottom of the
edge. A track that is properly adjusted will have
i00059427 a slack of 40 to 55 mm (1 5/8 to 2 1/8 inch ).
Track Adjustment - Adjust Tightening the Track

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.
Do not watch the relief valve to see if grease is es-

caping. Watch the track or track adjustment cylin-
der to see if the track is being loosened.
g00101754
Illustration 338
Loosen the relief valve one turn only. The track adjuster is located on the track frame.
If track does not loosen, close the relief valve and Wipe the fitting before you add grease.
contact your Caterpillar dealer.
NOTICE
Keeping the track properly adjusted will increase the
service life of the track and drive components.
Note: The track tension must be set according to

the current operating conditions. Keep the track as
slack as possible if the soil is heavy.
149
Maintenance Section
Track Adjustment - Inspect
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 N·m (25 lb ft) when

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

equalize the pressure.
4. Check the amount of sag. Adjust the track, as

needed.
If the correct adjustment cannot be achieved,

g00101757 consult your Caterpillar dealer.
Illustration 339
1. Add grease through valve fitting (1) until the i00824960

correct track tension is reached.
Track Adjustment - Inspect
2. Operate the machine back and forth in order to
equalize the pressure. SMCS Code: 4170-040
3. Check the amount of sag. Adjust the track, as

needed.
Loosening the Track
g00397520
Illustration 342
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,

g00101754
Illustration 340 see Operation and Maintenance Manual, “Track
The track adjuster is located on the track frame. Adjustment - Adjust”.
i01077733
Travel Alarm - Test

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

travel alarm.
1. Start the engine. Move the hydraulic activation

control lever to the UNLOCKED position.
g00101759
Illustration 341
150
Maintenance Section
Undercarriage - Check
2. Raise the implements in order to avoid any i00059532

obstacles. Make sure that there is adequate
overhead clearance. Undercarriage - Check
SMCS Code: 4150-535
g00560313
Illustration 343
g00101898
3. Use the travel levers or the travel pedals to move Illustration 345
the machine forward. The travel alarm should
sound. 1. Check the carrier rollers, the track rollers, and
the idler wheels for possible leakage.
4. Release the travel levers and the travel pedals in
order to stop the machine. 2. Check the surface of the track, the carrier rollers,
the track rollers, the idler wheels, the track
5. Use the travel levers and the travel pedals to shoes, and the drive sprockets. Look for signs of
move the machine backward. The travel alarm wear and loose mounting bolts.
should sound.
3. Listen for any abnormal noises while you are
moving slowly in an open area.
4. If abnormal wear exists or abnormal noises or

leaks are found, consult your Caterpillar dealer.
i00925362
V-Belts - Inspect/Adjust/
Replace
SMCS Code: 1357-025; 1357-040; 1357-510;
1359-025; 1359-040; 1359-510; 1361-025;
1361-040; 1361-510; 1405-025; 1405-040;
g00101993 1405-510; 7320-025; 7320-040; 7320-510
Illustration 344
6. Push the alarm cancel switch. The travel alarm NOTICE

should shut off. The V-belt must be tensioned correctly. Failure to ten-
sion the belt properly could cause damage to the belt
7. Stop the machine. Lower the implements. Move and/or to the air conditioner compressor.
the hydraulic activation control lever to the
LOCKED position. Stop the engine.
151
Maintenance Section
V-Belts - Inspect/Adjust/Replace
2. Apply approximately 98 N (22 lb) of force midway

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

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

bolt (1) and bracket bolt (2).
5. Move alternator (3) in order to achieve the

correct deflection.
Note: If necessary, use a pry bar in the square

hole in the mounting bracket to achieve the correct
g00287538 deflection.
Illustration 346
6. When the deflection is correct, tighten bolt
Your engine can be equipped with a water pump, (1) and bolt (2) to a torque of 145 ± 15 N·m
with a fan drive, and with an alternator. Your engine (110 ± 11 lb ft).
can also be equipped with accessory drive belts.
For maximum engine performance and maximum Note: If a new belt is installed, operate the engine
utilization of your engine, inspect the belts for wear at the rated engine speed for 30 minutes.
and for cracking. Check the belt tension. Adjust the
belt tension in order to minimize belt slippage. Belt 7. Check the deflection again. Readjust the belt,
slippage will decrease the belt life. Belt slippage if necessary.
will also cause poor performance of the alternator
and of any driven equipment.
Air Conditioner Belt
If new belts are installed, recheck the belt
adjustment after 30 minutes of operation. If two belts
or more are required for an application, replace
the belts in belt sets. If only one belt of a pair is
replaced, the new belt will carry more load. This is
due to the fact that the older belts are stretched.
The additional load on the new belt could cause the
new belt to break.
Water Pump Belt, Fan Drive Belt,

and Alternator Belt
g00287539
Illustration 348
(4) Nut
(5) Adjusting bolt
1. Apply approximately 98 N (22 lb) of force midway

between the pulleys.
2. Measure the deflection of the belt. The belt

should deflect 7 to 10 mm (0.3 to 0.4 inch).
3. If the deflection is not correct, loosen nut (4).

g00287535 4. Turn adjusting bolt (5) in order to achieve the
Illustration 347
(1) Mounting bolt correct deflection.
(2) Bracket bolt
(3) Alternator 5. When the deflection is correct, tighten nut (4) to
a torque of 38 ± 7 N·m (28 ± 5 lb ft).
1. Unlatch the engine hood and open the engine
hood.
152
Maintenance Section
Walk-Around Inspection
Note: If a new belt is installed, operate the engine Inspect the cooling system for any leaks, for faulty
at the rated engine speed for 30 minutes. hoses and for any trash buildup. Correct any leaks.
Remove any trash from the radiator.
6. Check the deflection again. Readjust the belt,
if necessary. Inspect all of the belts for the engine attachments.
Replace any belts that are worn, frayed, or broken.
hood.
i00729594
Walk-Around Inspection
SMCS Code: 7000
NOTICE
Accumulated grease and oil on a machine is a fire
hazard.
Remove debris with steam cleaning or high pressure

water, at the specified interval in the Maintenance In- Illustration 350 g00101870
terval Schedule or each time any significant quantity
of oil is spilled on the machine. Inspect the hydraulic system for leaks. Inspect the
tank, the cylinder rod seals, the hoses, the tubes,
Note: Watch closely for leaks. If you observe a leak, the plugs, the connections, and the fittings. Correct
find the source of the leak and correct the leak. If any leaks in the hydraulic system.
you suspect a leak or you observe a leak, check
the fluid levels more frequently. Inspect the final drives for leaks. Make any
necessary repairs. Check the oil level if leakage is
noticed.
Inspect the swing drive for leaks. Make any

necessary repairs.
Make sure that all covers and guards are securely

attached. Inspect the covers and the guards for
damage.
g00101867
Illustration 349
Inspect the hydraulic cylinders for damage or

for excessive wear. Inspect the linkage and the
bucket for damage or for excessive wear. Make any
necessary repairs.
Inspect the lights for broken bulbs and for broken

lenses. Replace any broken bulbs and any broken g00101987
lenses. Illustration 351
Inspect the engine compartment for any trash Inspect the steps, the walkways, and the handholds.
buildup. Remove any trash buildup from the engine Clean the steps, the walkways, and the handholds.
compartment. Make any necessary repairs.
Inspect the Falling Object Protective Structure

for damage. If repair is necessary, consult your
Caterpillar dealer. Tighten any loose bolts.
153
Maintenance Section
Water Pump Bearing - Lubricate
Inspect the operator compartment for trash buildup. i01077829

Check for trash buildup under the floorplate. Keep
these areas clean. Windows - Clean
Adjust the rearview mirrors for the best operator SMCS Code: 7310-070; 7340-070
vision.
Use commercially available window cleaning
solutions in order to clean the windows. Clean the
i00901120 outside of the windows from the ground, unless
handholds are available.
Water Pump Bearing -
Lubricate
SMCS Code: 1361-086-BD
Wipe all fittings before you apply lubricant.
g00566124
Illustration 354
Typical example
Use a pole with a squeegee in order to reach the

high areas of the window.
g00359072
Illustration 352 Cleaning Methods
hood.
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.
g00287813 Stubborn Dirt and Grease

Illustration 353
Wash the windows with a good grade of naphtha, of
2. Apply lubricant through the fitting. This fitting is isopropyl alcohol, or of Butyl Cellosolve. Then, wash
located on the water pump. the windows with soap and with water.
hood.
154
Maintenance Section
Window Washer Reservoir - Fill
i00936923 i01258249
Window Washer Reservoir - Fill Window Wiper -

SMCS Code: 7306-544-KE
Inspect/Replace
SMCS Code: 7305-040; 7305-510
NOTICE
When operating in freezing temperatures, use Inspect the condition of the wiper blades. Replace
Caterpillar or any commercially available nonfreezing the wiper blades if the wiper blades are worn or
window washer solvent. damaged or if streaking occurs.
g00393008
Illustration 355
The fluid bottle for the windshield washer is located

behind the cab.

machine.
g00287841
Illustration 356
2. Remove the filler cap.
3. Fill the washer fluid bottle with washer fluid

through the filler opening.
4. Install the filler cap.
6. The window washer nozzles can be adjusted

so that the washer fluid will be sprayed in the
desired direction.

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MAINTENANCE INTERVALS

Operation and Maintenance

i01486157 Every 50 Service Hours or Weekly

SMCS Code: 7000 Initial 100 Service Hours

When Required Initial 250 Service Hours

Every 1000 Service Hours or 6 Months

Every 1000 Service Hours of Partial Hammer

Every 2000 Service Hours or 1 Year

Every 3000 Service Hours or 3 Years

Every 6000 Service Hours or 6 Years

Air Conditioner - Test

Inhaling air conditioner refrigerant gas through a

3. Look at the receiver-dryer sight glass and note

• In sight glass (A), only a few bubbles

• In sight glass (B), many bubbles are present.

• In sight glass (C), small amounts of vapor are

Operation of the air conditioner without correct

The air conditioner should be kept ready for

4. Close the access door.

2. Open the access door on the left side of the

Air Conditioner/Cab Heater Battery - Clean

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the following

Battery, Battery Cable or

The air conditioner filter is on the lower left side of

1. Turn the engine start switch key to the OFF

3. Disconnect the negative battery cable at the

4. Disconnect the positive battery cable at the

5. Disconnect the battery cables at the battery

6. Make necessary repairs or replace the battery.

7. Connect the battery cable at the battery

Note: If the machine is operated under severe

a. Raise the implement until the implement is

b. Apply lubricant through fittings (1), (2), (3),

c. Lower the implement to the ground.

d. Apply a slight downward pressure on the

e. Apply lubricant through fittings (1), (2), (3),

g00102057 4. To lubricate the head end of the stick cylinder,

7. Apply lubricant through fitting (10). This fitting

8. Apply lubricant through fittings (11) and (12).

3. Fittings (1) and (2) lubricate the lower boom

Use Steps 3.a through 3.e to ensure proper

9. Apply lubricant through fitting (13). Fitting (13) is

When performing this adjustment, put the hy-

NOTICE Illustration 207

2. Slowly operate the swing control lever until stick

3. Place the hydraulic activation control lever in the

4. Measure bucket clearance (3), which is the

7. After the correct number of shims has been

8. After installation, make sure that bucket

b. Align extractor (5) with the pin.

Block the bucket before changing bucket tips or

2. Clean the adapter and the pin.

d. Slide pin holder (10) away from the pin and

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

6. After you drive the pin, make sure that the

4. Install the new bucket tip onto the adapter.

Note: The bucket tip can be rotated by 180

5. Drive the pin through the bucket tip. The pin

3. Install the new side cutters or the rotated side

Cab Air Filter - Clean/Replace

a. Insert the pin through the bucket tooth.

b. Place the Pin-Master over the bucket tooth