314

MAINTENANCE INTERVALS
Operation and Maintenance Manual Excerpt
2010 Caterpillar All Rights Reserved
SEBU8266-06 October 2010
Operation and Maintenance Manual

314D CR Excavator
BYJ1-Up (Machine) TXN1-Up (Machine) WLN1-Up (Machine) PDP1-Up (Machine) SBP1-Up (Machine) XHR1-Up (Machine) SSZ1-Up (Machine)
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188 Maintenance Section Maintenance Interval Schedule
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Maintenance Interval Schedule

SMCS Code: 7000 Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the following items: performance of maintenance, including all adjustments, the use of proper lubricants, uids, lters, and the replacement of components due to normal wear and aging . Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components. Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, in order to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance. Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed. Note: If Cat HYDO Advanced 10 hydraulic oil is used, the hydraulic oil change interval will change. The normal interval of 2000 hours is extended to 3000 hours. SOS services may extend the oil change to a longer interval. Consult your Caterpillar dealer for details.
Every 10 Service Hours or Daily for First 100 Hours

Blade Linkage - Lubricate ................................... 193 Boom and Stick Linkage - Lubricate ................... 193 Bucket Linkage - Lubricate ................................. 197
Every 10 Service Hours or Daily

Cooling System Coolant Level - Check .............. 205 Engine Oil Level - Check ..................................... 211 Fuel System Water Separator - Drain ................. 221 Fuel Tank Water and Sediment - Drain ............... 222 Hydraulic System Oil Level - Check ................... 235 Indicators and Gauges - Test .............................. 238 Seat Belt - Inspect .............................................. 240 Track (Rubber) - Inspect/Replace ....................... 245 Track Adjustment - Inspect ................................. 247 Travel Alarm - Test .............................................. 247 Undercarriage - Check ........................................ 248
Every 10 Service Hours or Daily for Machines Used in Severe Applications

Blade Linkage - Lubricate ................................... 193 Bucket Linkage - Lubricate ................................. 197
Every 100 Service Hours or 2 Weeks

Blade Linkage - Lubricate ................................... 193 Bucket Linkage - Lubricate ................................. 197
Every 100 Service Hours or 2 Weeks for Machines Used in Severe Applications
Boom and Stick Linkage - Lubricate ................... 193 Hydraulic System Oil Filter (Return) - Replace ... 231
When Required
Air Conditioner/Cab Heater Filter (Recirculation) Inspect/Replace ................................................ 190 Battery - Recycle ................................................ 190 Battery or Battery Cable - Inspect/Replace ........ 191 Blade Cutting Edges - Inspect/Replace .............. 192 Bucket Linkage - Inspect/Adjust ......................... 196 Bucket Tips - Inspect/Replace ............................ 197 Cab Air Filter (Fresh Air) - Clean/Replace .......... 199 Camera - Clean/Adjust ....................................... 200 Circuit Breakers - Reset ...................................... 202 Engine Air Filter Primary Element - Clean/ Replace ............................................................. 208 Engine Air Filter Secondary Element - Replace .. 210 Film (Product Identication) - Clean ................... 214 Fuel System - Prime ........................................... 217 Fuses - Replace .................................................. 222 High Intensity Discharge Lamp (HID) - Replace .. 224 Oil Filter - Inspect ................................................ 238 Radiator Core - Clean ......................................... 239 Track Adjustment - Adjust ................................... 246 Window Washer Reservoir - Fill .......................... 248 Window Wiper - Inspect/Replace ........................ 249 Windows - Clean ................................................. 249
Every 100 Service Hours of Continuous Hammer Use

Hydraulic System Oil Filter (Case Drain) Replace ............................................................. 229 Hydraulic System Oil Filter (Pilot) - Replace ....... 230 Hydraulic System Oil Filter (Return) - Replace ... 231
Initial 250 Service Hours

Engine Valve Lash - Check ................................. Final Drive Oil - Change ..................................... Hydraulic System Oil Filter (Case Drain) Replace ............................................................. Hydraulic System Oil Filter (Pilot) - Replace ....... Hydraulic System Oil Filter (Return) - Replace ... Swing Drive Oil - Change ................................... 214 215 229 230 231 241
Every 250 Service Hours

Engine Oil Sample - Obtain ................................ 212 Final Drive Oil Sample - Obtain .......................... 216
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189 Maintenance Section Maintenance Interval Schedule
Every 250 Service Hours for Machines Used in Severe Applications

Fuel System Primary Filter (Water Separator) Element - Replace ............................................ 218 Fuel System Secondary Filter - Replace ............ 219
Every 1000 Service Hours of Partial Hammer Use (50% of Service Hours)
Hydraulic System Oil - Change ........................... 224
Every 2000 Service Hours or 1 Year

Final Drive Oil - Change ..................................... Hydraulic System Oil - Change ........................... Hydraulic Tank Screen - Clean ........................... Receiver Dryer (Refrigerant) - Replace .............. Swing Gear - Lubricate ....................................... 215 224 236 239 244
Every 250 Service Hours or Monthly

Belts - Inspect/Adjust/Replace ............................ Condenser (Refrigerant) - Clean ........................ Final Drive Oil Level - Check .............................. Swing Bearing - Lubricate ................................... Swing Drive Oil Level - Check ............................ 191 202 216 241 242
Every Year
Cooling System Coolant Sample (Level 2) Obtain ............................................................... 207
Every 250 Service Hours of Partial Hammer Use (50% of Service Hours)
Hydraulic System Oil Filter (Case Drain) Replace ............................................................. 229 Hydraulic System Oil Filter (Pilot) - Replace ....... 230 Hydraulic System Oil Filter (Return) - Replace ... 231
Every 3000 Service Hours or 18 Months

Initial 500 Hours (for New Systems, Relled Systems, and Converted Systems)
Cooling System Coolant Sample (Level 2) Obtain ............................................................... 207
Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 241
Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .. 204
Every 500 Service Hours

Cooling System Coolant Sample (Level 1) Obtain ............................................................... 206 Hydraulic System Oil Sample - Obtain ............... 236 Swing Drive Oil Sample - Obtain ........................ 243
Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 202

Engine Crankcase Breather - Clean .................... 211 Engine Oil and Filter - Change ........................... 213 Fuel System Primary Filter (Water Separator) Element - Replace ............................................ 218 Fuel System Secondary Filter - Replace ............ 219 Fuel System Third Filter - Replace ..................... 220 Fuel Tank Cap and Strainer - Clean ................... 221
Every 600 Service Hours of Continuous Hammer Use


Battery - Clean .................................................... Battery Hold-Down - Tighten ............................... Boom and Stick Linkage - Lubricate ................... Engine Valve Lash - Check ................................. Hydraulic System Oil Filter (Case Drain) Replace ............................................................. Hydraulic System Oil Filter (Pilot) - Replace ....... Hydraulic System Oil Filter (Return) - Replace ... Rollover Protective Structure (ROPS) - Inspect .. Swing Drive Oil - Change ................................... 190 190 193 214 229 230 231 240 241
190 Maintenance Section Air Conditioner/Cab Heater Filter (Recirculation) - Inspect/Replace
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Air Conditioner/Cab Heater Filter (Recirculation) Inspect/Replace

SMCS Code: 1054-040-A/C; 1054-510-A/C NOTICE An air recirculation lter element plugged with dust will result in decreased performance and service life to the air conditioner or cab heater. To prevent decreased performance, clean the lter element, as required.
4. Clean the lter element with a maximum of 200 kPa (30 psi) pressure air. 5. After you clean the lter element, inspect the lter element. If the lter element is damaged or badly contaminated, use a new lter element. Make sure that the lter element is dry. NOTICE Failure to reinstall the lter element for the air conditioning system will contaminate and damage the system components.
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Battery - Clean
SMCS Code: 1401-070 Clean the battery surface with a clean cloth. Keep the terminals clean and keep the terminals coated with petroleum jelly. Install the post cover after you coat the terminal post with petroleum jelly.
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Battery - Recycle
SMCS Code: 1401-561
Illustration 251
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Always recycle a battery. Never discard a battery. Always return used batteries to one of the following locations:
The recirculation lter is on the left side of the operator seat.
A battery supplier An authorized battery collection facility Recycling facility

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Battery Hold-Down - Tighten

SMCS Code: 7257
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Illustration 252
Tighten the hold-downs for the battery in order to prevent the batteries from moving during machine operation.
1. To remove the lter element, remove the cover screw and the lter cover. 2. To remove the lter, pull the lter away from the operator seat. 3. Refer to Operation and Maintenance Manual, General Hazard Information before using pressure air to clean the air lter element.
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191 Maintenance Section Battery or Battery Cable - Inspect/Replace
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Battery or Battery Cable Inspect/Replace

SMCS Code: 1401-040; 1401-510; 1401-561; 1401; 1402-040; 1402-510
Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510; 1357; 1358-025; 1358-510; 1359-025-BE; 1359-025; 1359-040-BE; 1359-040; 1359-510-BE; 1359-510; 1361-025-BE; 1361-025; 1361-040; 1361-040-BE; 1361-510; 1361-510-BE; 1397-025; 1397-040; 1397-510; 1405-025; 1405-025-BE; 1405-036; 1405-040-BE; 1405-040; 1405-510; 1405-510-BE; 1802-025; 1802-510
Personal injury can result from battery fumes or explosion. Batteries give off ammable fumes that can explode. Electrolyte is an acid and can cause personal injury if it contacts the skin or eyes. Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jumper cable ends to contact each other or the engine. Improper jumper cable connections can cause an explosion. Always wear protective glasses when working with batteries. 1. Turn all of the switches to the OFF position. Turn the engine start switch key to the OFF position. 2. Turn the battery disconnect switch to the OFF position. Remove the key. 3. Disconnect the negative battery cable at the battery. 4. Disconnect the positive battery cable at the battery. 5. Disconnect the battery cables at the battery disconnect switch. The battery disconnect switch is connected to the machine frame. 6. Make necessary repairs or replace the battery. 7. Connect the battery cable at the battery disconnect switch. 8. Connect the positive battery cable of the battery. 9. Connect the negative battery cable of the battery. 10. Install the key and turn the battery disconnect switch to the ON position.
Illustration 253
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Your engine is equipped with a water pump, with a fan drive, and with an alternator. Your engine can also be equipped with an air conditioner belt. For maximum engine performance and maximum utilization of your engine, inspect the belts for wear and for cracking. Check the belt tension. Adjust the belt tension in order to minimize belt slippage. Belt slippage will decrease the belt life. Belt slippage will also cause poor performance of the alternator and of any driven equipment. If new belts are installed, recheck the belt adjustment after 30 minutes of operation. If two belts or more are required for an application, replace the belts in belt sets. If only one belt of a matched set is replaced, the 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

1. Open the engine hood.
192 Maintenance Section Blade Cutting Edges - Inspect/Replace
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Illustration 254 (1) Mounting bolt (2) Bracket bolt (3) Adjusting bolt
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Illustration 255 (4) Nut (5) Adjusting bolt
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2. Apply approximately 98 N (22 lb) force midway between the pulleys. 3. Measure the deection of the belt. The belt should deect 10 to 12 mm (0.4 to 0.5 inch). 4. If the deection is not correct, loosen alternator mounting bolt (1) and bracket bolt (2). Turn adjusting bolt (3) in order to adjust the belt tension. 5. When the adjustment is correct, tighten bolt (1) and bolt (2). 6. Check the deection of the belt again. 7. If a new belt is installed, run the engine at rated speed for thirty minutes. Check the belt adjustment. Readjust the belt, if necessary.
1. Apply approximately 100 N (22 lb) force midway between the pulleys. 2. Measure the deection of the belt. The belt should deect 7 to 10 mm (0.3 to 0.4 inch). 3. If the deection is not correct, loosen nut (4). Turn 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 Nm (28 5 lb ft). 5. Check the deection 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.
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Air Conditioner Belt (If Equipped)

NOTICE The V-belt must be tensioned correctly. Failure to tension the belt properly could cause damage to the belt and/or to the air conditioner compressor.
Blade Cutting Edges Inspect/Replace (If Equipped)

SMCS Code: 6801
Personal injury or death can result from a falling blade. Block the blade before changing the cutting edges and the end bits. Check the cutting edge of the blade and the end bits of the blade for wear. If any of the parts have signs of unusual wear or damage, replace the part.
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193 Maintenance Section Blade Linkage - Lubricate
Wipe all ttings before you apply lubricant.
Illustration 256 (1) (2) (3) (4) (5) Bolt Cutting edge End bit Nut Washer
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Illustration 257
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1. Apply lubricant through ttings (1). These ttings are located on the rod end of the blade cylinder. 2. Apply lubricant through ttings (2). These ttings are located on the bar that supports the blade. 3. Apply lubricant through ttings (3). These ttings are located on the head end of the blade cylinder.
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1. Raise the blade and place blocking underneath the blade. 2. Lower the blade onto the blocking. 3. Remove bolts (1), washers (5) and nuts (4). 4. Remove cutting edge (2) and end bits (3). 5. Clean the surface between the cutting edge and the end bits. 6. Turn the cutting edge and/or the end bits upside-down if those edges are not worn. 7. If both sides of the cutting edge and the end bits are worn, replace the parts with new parts. 8. Install the new parts or the rotated parts with bolts (1). Tighten the bolts to a torque of 270 40 Nm (200 30 lb ft). 9. Raise the blade and remove the blocking. 10. Lower the blade to the ground. 11. After a few hours of operation, tighten bolts (1) to the torque that is specied in Step 8.
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Boom and Stick Linkage Lubricate

SMCS Code: 6501-086; 6502-086 Note: Caterpillar recommends the use of 5% molybdenum grease for lubricating the boom, stick and bucket control linkage. Refer to Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations for more information on molybdenum grease. Apply lubricant through all ttings after operation under water. Wipe all ttings before you apply lubricant.
Blade Linkage - Lubricate

SMCS Code: 6060-086 Note: Caterpillar recommends the use of 5% molybdenum grease for lubricating the blade linkage. Refer to Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations for more information on molybdenum grease.
194 Maintenance Section Boom and Stick Linkage - Lubricate
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Standard Boom (If Equipped)
Illustration 260 Illustration 258

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1. Apply lubricant through the tting at the base of each boom cylinder.
5. Apply lubricant through tting (6). Fitting (6) is at the connection point of the boom and of the stick.

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2. The ttings are at the base of the boom. The ttings can be serviced from the platform on top of the storage box. To lubricate the lower boom bearings, apply lubricant through ttings (1) and (2). 3. Apply lubricant through ttings (3) and (4) for the boom cylinder rod. 4. Apply lubricant through tting (5) for the stick cylinder head. Note: To ensure proper lubrication of the lower boom bearings and of the boom cylinder rod end bearings, lubricant should be applied through ttings (1), (2), (3), and (4). Apply lubricant rst when the boom is raised and any attachment is suspended. Then apply lubricant when the boom is lowered and the attachment is rested on the ground with a slight downward pressure.
6. Apply lubricant through tting (7) on the stick cylinder rod, tting (8) at the connection point of the boom and of the stick, and tting (9) at the bucket cylinder head end.
Offset Boom (If Equipped)

1. Perform step 1 through step 4 of the Standard Boom procedure.
Illustration 262
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195 Maintenance Section Boom and Stick Linkage - Lubricate
2. Apply lubricant through ttings (10) and (11) for the upper boom support.

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3. Apply lubricant through tting (12) for the offset cylinder rod. Apply lubricant through ttings (13) and (14) for the offset bar.
6. Apply lubricant through ttings (20) and (21). Fittings (20) and (21) are located at the connection point of the cylinder and the stick.

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7. Apply lubricant through tting (22) at the bucket cylinder head.
4. Apply lubricant through ttings (15) and (16). Fittings (15) and (16) are located at the connection point of the upper boom and the cylinder.
Boom Cylinder Guard
Illustration 265
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Illustration 268
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5. Apply lubricant through ttings (17) and (18) on the stick cylinder head, and tting (19) at the stick cylinder rod.
1. Apply lubricant to the sliding surfaces (23) of the boom cylinder guard.
196 Maintenance Section Bucket Linkage - Inspect/Adjust
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Bucket Linkage Inspect/Adjust

SMCS Code: 6513-025; 6513-040
Unexpected machine movement can cause injury or death. 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 hydraulic 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.
Illustration 270 Area for linkage adjustment
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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 position and stop the engine. 4. Measure bucket clearance (3), which is the existing total clearance. 5. Determine the number of shims that need to be removed from shims (4) by using the following calculation: Subtract 0.5 mm (0.02 inch ) or 1.0 mm (0.04 inch) from bucket clearance (3).
Illustration 269 (1) No gap (2) Stick boss (3) Bucket clearance (4) Shims (5) Pin (6) Plate (7) Bolts (8) Washers (9) Location (10) Flange (11) Bucket boss
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6. Remove the appropriate number of shims at location (9) in order to meet the above thickness. Make sure that you use a minimum of three 0.5 mm (0.02 inch) shims. To remove the shims, remove bolts (7), washers (8), and plate (6). 7. After the correct number of shims has been removed and pin (5) is aligned with the pin hole, install plate (6), washers (8), and bolts (7). Tighten bolts (7) to a torque of 240 40 Nm (175 30 lb ft). 8. After installation, make sure that bucket clearance (3) is still correct.
The clearance of the bucket control linkage on this machine can be adjusted by shimming. If the 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).
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197 Maintenance Section Bucket Linkage - Lubricate
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Bucket Tips
Bucket Linkage - Lubricate

SMCS Code: 6513-086 Note: Caterpillar recommends the use of 5% molybdenum grease for lubricating the bucket control linkage. Refer to Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations for more information on molybdenum grease. Wipe all ttings before you apply lubricant.
Illustration 272 (1) Usable (2) Replace this bucket tip. (3) Overworn
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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.
Illustration 271
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Use a hammer and a punch from the retainer

side of the bucket to drive out the pin. 1.c for the procedure.
Note: Completely ll all cavities of the bucket control linkage with grease when you initially install a bucket. 1. Apply lubricant through ttings for the linkages (1), (2), and (3). 2. Apply lubricant through ttings for the bucket (4), (5), and (6). Note: Service the above ttings after you operate the bucket under water.
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Use a Pin-Master. Follow Step 1.a through Step
Bucket Tips - Inspect/Replace

SMCS Code: 6805-040; 6805-510
Illustration 273 (4) Back of Pin-Master (5) Extractor
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Personal injury or death can result from bucket falling. Block the bucket before changing bucket tips or side cutters.
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.
198 Maintenance Section Bucket Tips - Inspect/Replace
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Illustration 274 (6) Retainer assembly (7) Adapter
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Illustration 276 (8) Pin
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2. Clean the adapter and the pin. 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.
a. Insert pin (8) through the bucket tip.
Illustration 277 (4) Back of Pin-Master (9) Pin holder (10) Pin setter
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Illustration 275
4. Install the new bucket tip onto the adapter. Note: The bucket tips can be rotated by 180 degrees in order to allow the tip to wear evenly. You may also move the tips from the outside teeth to the inside teeth. Check the tips often. If wear is present on the tips, rotate the tips. The outside teeth generate the most wear. 5. Drive the pin through the bucket tip. The pin can be installed by using one of the following methods:
b. Place the Pin-Master over the bucket tips so that the pin will t into the counterbore of the pin holder (9). c. Strike the Pin-Master with a hammer at the back of the tool (4) in order to insert the pin. d. Slide pin holder (9) away from the pin and rotate the tool slightly in order to align pin setter (10) with the pin.
From the same side of the retainer, drive the pin

through the bucket tip, the retainer assembly, and the adapter. 5.e for the procedure.
Use a Pin-Master. Follow Step 5.a through Step
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199 Maintenance Section Cab Air Filter (Fresh Air) - Clean/Replace
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Cab Air Filter (Fresh Air) Clean/Replace

SMCS Code: 7342-070; 7342-510 S/N: BYJ1-Up S/N: PDP1-Up S/N: SBP1-Up
Illustration 278 Final assembly of pin into bucket tip.
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e. Strike the end of the tool until the pin is fully inserted.
Side Cutters
Illustration 280 (1) Air Filter (2) Duct
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The fresh air lter is located behind the operator's seat. 1. Remove the air lter from the duct by pulling the air lter upward.
Illustration 279 Bucket With Side Cutters (A) Side cutters
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2. Clean the air lter with a maximum of 200 kPa (30 psi) pressure air. 3. After you clean the air lter, inspect the air lter. If the air lter is damaged or badly contaminated, use a new air lter. 4. Install the air lter. Note: Make sure that the arrow on top of the air lter is facing forward.
1. Remove the mounting bolts and the side cutters. 2. Clean the mounting surface of the side plate on the bucket and of the side cutter. Remove any burrs or protrusions on the mating surfaces. 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. 5. Torque the mounting bolts to the correct specication.
200 Maintenance Section Cab Air Filter (Fresh Air) - Clean/Replace
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5. Install the air lter and the lter cover.

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Cab Air Filter (Fresh Air) Clean/Replace

SMCS Code: 7342-070; 7342-510 S/N: TXN1-Up S/N: WLN1-Up S/N: XHR1-Up S/N: SSZ1-Up
Camera - Clean/Adjust
SMCS Code: 7348
Failure to use an appropriate external ladder or an appropriate platform for direct access to the rear view camera could result in slipping and falling which could result in personal injury or death. Be sure to use an appropriate external ladder or an appropriate platform for direct access to the rear view camera. The machine's counterweight and the engine hood are not approved as a maintenance platforms.
Unexpected machine movement can cause injury or death.

Illustration 281
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The cab air lter is located on the left side of the cab. 1. Use the ignition key in order to open the access panel.
In order 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 hydraulic lockout control. When maintenance or servicing of the rear view camera is required follow these steps. 1. Park the machine on a level surface. 2. Place the work tool on the level surface. 3. Move the hydraulic lockout control to the Locked position. 4. Turn the engine start switch to the OFF position and remove the engine start switch key.
Illustration 282 (1) Air lter
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5. Turn the battery disconnect switch to theOFF position and remove the battery disconnect switch key.
2. Remove air lter (1). 3. Clean the air lter with a maximum of 200 kPa (30 psi) pressure air. 4. After you clean the air lter, inspect the air lter. If the air lter is damaged or badly contaminated, use a new air lter.
Clean Camera Lens

If necessary, clean the camera lens before you operate the machine. Use a soft cloth for cleaning.
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201 Maintenance Section Camera - Clean/Adjust
Adjust the Area of Visibility

If the camera displays an undesired view, adjust the area of the visibility.
Illustration 283 (1) Cover (2) Bolt
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Illustration 285
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3. Adjust the area of the visibility of the camera so that a 1.5 m (5 ft 11 inch) tall obstacle which is 1 m (3 ft) behind the counterweight can be seen. 4. Tighten the 2 bolts (3) to a torque of 0.5 0.05 Nm (4 0.4 lb in). 5. Tighten the 2 bolts (2) to a torque of 55 10 Nm (40 7 lb ft) in order to x the cover (1).
Illustration 284 (3) Bolt
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1. Remove the 2 bolts (2) in order to remove the cover (1). 2. Unfasten the 2 bolts (3).
202 Maintenance Section Circuit Breakers - Reset
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Circuit Breakers - Reset

SMCS Code: 1420-529
Illustration 287 Typical example
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1. Inspect the condenser for debris. Clean the condenser, if necessary. 2. Use clean water to wash off all dust and dirt from the condenser.
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Illustration 286
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The circuit breaker is located behind the access door on the left side of the machine.
Cooling System Coolant (ELC) - Change

SMCS Code: 1350-044 NOTICE Do not change the coolant until you read and understand the cooling system information in Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations. Failure to do so could result in damage to the cooling system components. NOTICE Mixing ELC with other products will reduce the effectiveness of the coolant. This could result in damage to cooling system components. If Caterpillar products are not available and commercial products must be used, make sure they have passed the Caterpillar EC-1 specication for pre-mixed or concentrate coolants and Caterpillar Extender. Note: This machine was lled at the factory with Cat ELC (Extended Life Coolant).
Alternator Circuit (1) 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 rectier. The circuit breaker for the alternator has a capacity of 60 Amp. Circuit Breaker Reset Push in the button in order to reset the circuit breaker. If the electrical system is working properly, the button will remain depressed. If the button does not remain depressed, check the appropriate electrical circuit. Repair the electrical circuit, if necessary.
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Condenser (Refrigerant) Clean

SMCS Code: 1805-070 NOTICE If excessively dirty, clean condenser with a brush. To prevent damage or bending of the ns, do not use a stiff brush. Repair the ns if found defective.
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203 Maintenance Section Cooling System Coolant (ELC) - Change
If the coolant in the machine is changed to Extended Life Coolant from another type of coolant, see Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations.
Note: Refer to Operation and Maintenance Manual, General Hazard Information for information that pertains to containing uid spillage. 4. Remove the access cover that is underneath the radiator. 5. Open the drain valve and allow the coolant to drain into a suitable container. The drain valve is located on the bottom of the radiator. 6. Flush the cooling system. Follow Step 6.a through Step 6.h in order to properly ush the cooling system. a. Close the drain valve. b. Fill the cooling system with clean water.
Illustration 288
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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. h. Flush the radiator with clean water until the draining water is transparent. 7. Close the drain valve and install the access cover underneath the radiator. 8. Add the Extended Life Coolant. Refer to the following topics:
1. Open the radiator access door that is located behind the cab.
Illustration 289
g01507923
2. Slowly loosen the pressure cap that is on the radiator in order to release pressure from the cooling system. 3. Remove the pressure cap.
Special Publication, SEBU6250, Caterpillar

Machine Fluids Recommendations (Rell)
Operation and Maintenance Manual, Capacities

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 ller pipe. 11. Inspect the gasket of the cooling system pressure cap. If the gasket is damaged, replace the pressure cap.
Illustration 290
g00762033
12. Install the cooling system pressure cap.
204 Maintenance Section Cooling System Coolant Extender (ELC) - Add
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13. Stop the engine.
i02980221
Cooling System Coolant Extender (ELC) - Add

SMCS Code: 1352; 1353; 1395
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 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 requirements. Use a Coolant Conditioner Test Kit in order to check the concentration of the coolant. NOTICE Mixing ELC with other products will reduce the effectiveness of the coolant. This could result in damage to cooling system components. If Caterpillar products are not available and commercial products must be used, make sure they have passed the Caterpillar EC-1 specication for pre-mixed or concentrate coolants and Caterpillar Extender. Note: This machine was lled at the factory with Caterpillar Extended Life Coolant. 1. Park the machine on level ground. 2. Stop the engine.
Illustration 291 (1) FULL (2) LOW
g00545226
14. Check the coolant reservoir. Maintain the coolant level between FULL mark (1) and LOW mark (2). 15. If additional coolant is necessary, remove the reservoir cap and add the appropriate coolant solution. 16. Install the reservoir cap. 17. Close the radiator access door that is located behind the cab.
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205 Maintenance Section Cooling System Coolant Level - Check
7. Inspect the gasket of the cooling system pressure cap. If the gasket is damaged, replace the pressure cap. 8. Install the cooling system pressure cap. 9. Close the radiator access door.
i02980232
Cooling System Coolant Level - Check

Illustration 292
g01507902
SMCS Code: 1350-040; 1350-535-FLV; 1395-535-FLV
3. Open the radiator access door that is located behind the cab. 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.
Illustration 293
g01507923
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.
4. Make sure that the cooling system has cooled down. Loosen the cooling system pressure cap slowly in order to relieve system pressure. Remove the pressure cap. Note: Refer to Operation and Maintenance Manual, General Hazard Information for information on containing uid spillage. 5. It may be necessary to drain some coolant from the radiator so that Caterpillar Extender can be added to the cooling system. Note: Always discard drained uids 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:
Illustration 294
g01507902

Machine Fluids Recommendations (Rell)
1. Openthe radiator access door that is located behind the cab.
Operation and Maintenance Manual, Capacities
206 Maintenance Section Cooling System Coolant Sample (Level 1) - Obtain
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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 ller pipe. f. Inspect the condition of the gasket on the pressure cap. If the gasket is damaged, replace the pressure cap. g. Install the cooling system pressure cap.
Illustration 295 (1) FULL level (2) LOW level
g00545226
h. Stop the engine. i. Close the radiator access door. Note: Refer to Operation and Maintenance Manual, General Hazard Information for information on containing uid spillage. 3. If additional coolant is necessary, remove the reservoir cap and add the appropriate coolant solution. 4. Install the reservoir cap. 5. Close the left access door.
i02626212
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.
Cooling System Coolant 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 lled with Cat ELC (Extended Life Coolant). Cooling systems that are lled with Cat ELC should have a Coolant Sample (Level 2) that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule. Note: Obtain a Coolant Sample (Level 1) if the cooling system is lled with any other coolant instead of Cat ELC. This includes the following types of coolants.
Illustration 296
g01507923
b. Slowly loosen the cooling system pressure cap in order to relieve system pressure. Remove the pressure cap. Note: Refer to Operation and Maintenance Manual, General Hazard Information for information on containing uid spillage. c. Add the appropriate coolant solution to the cooling system. Refer to the following topics:
Commercial long life coolants that meet the

Caterpillar Engine Coolant Specication -1 (Caterpillar EC-1)

Machine Fluids Recommendations Capacities (Rell)
Cat Diesel Engine Antifreeze/Coolant (DEAC) Commercial heavy-duty coolant/antifreeze
Operation and Maintenance Manual,
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207 Maintenance Section Cooling System Coolant Sample (Level 2) - Obtain
Complete the information on the label for the

NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. Note: Level 1 results may indicate a need for Level 2 Analysis. sampling bottle before you begin to take the samples. bags.
Keep the unused sampling bottles stored in plastic Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples from any other location. are ready to collect the sample.
Keep the lids on empty sampling bottles until you 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. For additional information about coolant analysis, see Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer.
i02062059
Cooling System Coolant Sample (Level 2) - Obtain

SMCS Code: 1395-008; 1395-554; 7542 Obtain the sample of the coolant as close as possible to the recommended sampling interval. Supplies for collecting samples can be obtained from your Caterpillar dealer. Refer to Operation and Maintenance Manual, Cooling System Coolant Sample (Level 1) - Obtain for the guidelines for proper sampling of the coolant. Submit the sample for Level 2 analysis. Reference: For additional information about coolant analysis, refer to Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer.
Illustration 297
g01316663
The coolant sampling valve is located near the cooling system hose.
Obtain the sample of the coolant as close as possible to the recommended sampling interval. In order to receive the full effect of SOS analysis, you must establish a consistent trend of data. In order to establish a pertinent history of data, perform consistent samplings that are evenly spaced. Supplies for collecting samples can be obtained from your Caterpillar dealer. Use the following guidelines for proper sampling of the coolant:
208 Maintenance Section Engine Air Filter Primary Element - Clean/Replace
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i02530911
Engine Air Filter Primary Element - Clean/Replace

SMCS Code: 1054-070; 1054-510 If a warning and a pictograph is displayed on the message display or if the exhaust is black, check the primary lter. 1. Open both access doors on the left side of the machine.
Illustration 300
g00101415
4. Remove the primary lter element from the air cleaner housing. 5. Clean the air cleaner cover and the inside of the air cleaner housing. 6. Inspect the O-ring seal on the air cleaner cover. Replace the O-ring seal if the O-ring seal is worn or damaged. 7. Install the clean primary lter.
Illustration 298
g01266485
Note: Refer to Cleaning Primary Air Filter Elements. 8. Install the air cleaner cover and close the latches securely.
2. Squeeze the outlet tube (1) slightly in order to purge the dirt from the outlet tube.
Illustration 299
g01266486
Illustration 301
g00101416
3. Loosen the cover latches (2) and remove the air cleaner cover.
Note: Install the air cleaner cover properly. The arrows must point upward. 9. Change the lter if any of the following conditions occurs:
Restricted Air Filter indicator on the monitor

panel still comes on. of a primary lter.
Exhaust smoke is still black after the installation
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209 Maintenance Section Engine Air Filter Primary Element - Clean/Replace
10. Close the access doors.
Pressurized Air
Pressurized air can be used to clean primary air lter elements that have not been cleaned more than two times. Pressurized air will not remove deposits of carbon and oil. Use ltered, dry air with a maximum pressure of 207 kPa (30 psi).
Cleaning Primary Air Filter Elements

NOTICE Caterpillar recommends certied air lter cleaning services available at participating Caterpillar dealers. The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufcient lter life. Observe the following guidelines if you attempt to clean the lter element: Do not tap or strike the lter element in order to remove dust. Do not wash the lter element. Use low pressure compressed air in order to remove the dust from the lter element. Air pressure must not exceed 207 kPa (30 psi). Direct the air ow up the pleats and down the pleats from the inside of the lter element. Take extreme care in order to avoid damage to the pleats. Do not use air lters with damaged pleats, gaskets, or seals. Dirt entering the engine will cause damage to engine components. When the primary air lter element is cleaned, check for rips or tears in the lter material. Replace the primary air lter element after the primary air lter element has been cleaned six times. The primary air lter element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings. NOTICE Do not clean the air lter elements by bumping or tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets, or seals. Damaged elements will allow dirt to pass through. Engine damage could result. Visually inspect the primary air lter elements before cleaning. Inspect the air lter elements for damage to the seal, the gaskets, and the outer cover. Discard any damaged air lter elements. There are two common methods that are used to clean primary air lter elements:
Illustration 302
g00281692
Note: When the primary air lter elements are cleaned, always begin with the clean side (inside) in order to force dirt particles toward the dirty side (outside). Aim the hose so that the air ows inside the element along the length of the lter in order to help prevent damage to the paper pleats. Do not aim the stream of air directly at the primary air lter element. Dirt could be forced further into the pleats.
Vacuum Cleaning
Vacuum cleaning is another method for cleaning primary air lter elements which require daily cleaning because of a dry, dusty environment. Cleaning with pressurized air is recommended prior to vacuum cleaning. Vacuum cleaning will not remove deposits of carbon and oil.
Pressurized air Vacuum cleaning
210 Maintenance Section Engine Air Filter Secondary Element - Replace
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Inspecting the Primary Air Filter Elements
Do not use paint, a waterproof cover, or plastic as a protective covering for storage. An air ow restriction may result. To protect against dirt and damage, wrap the primary air lter elements in Volatile Corrosion Inhibited (VCI) paper. Place the primary air lter element into a box for storage. For identication, mark the outside of the box and mark the primary air lter element. Include the following information:
Date of cleaning Number of cleanings

Store the box in a dry location.
Illustration 303
g00281693 i01516547
Inspect the clean, dry primary air lter element. Use a 60 watt blue light in a dark room or in a similar facility. Place the blue light in the primary air lter element. Rotate the primary air lter element. Inspect the primary air lter element for tears and/or holes. Inspect the primary air lter element for light that may show through the lter material. If it is necessary in order to conrm the result, compare the primary air lter element to a new primary air lter element that has the same part number. Do not use a primary air lter element that has any tears and/or holes in the lter material. Do not use a primary air lter element with damaged pleats, gaskets or seals. Discard damaged primary air lter elements.
Engine Air Filter Secondary Element - Replace

SMCS Code: 1054-510 NOTICE Always replace the secondary lter element. Never attempt to reuse the secondary lter element by cleaning the element. When the primary lter element is replaced, the secondary lter element should be replaced. The secondary lter element should also be replaced if the air lter restriction warning appears on the message display after the installation of a clean primary lter element or if exhaust smoke is still black. 1. Open the access door on the left side of the machine. 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 lter element from the air cleaner housing.
Storing Primary Air Filter Elements

If a primary air lter element that passes inspection will not be used, the primary air lter element can be stored for future use.
Illustration 304
g00281694
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211 Maintenance Section Engine Crankcase Breather - Clean
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, nonammable 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).
Illustration 305
g00101451
8. Close and latch the engine hood.

i02625564
3. Remove the secondary lter element. 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 lter element. 7. Install the primary lter element. 8. Install the air cleaner cover and close the latches securely. 9. Close the access door.
i02712013
Engine Oil Level - Check

SMCS Code: 1000-535
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. NOTICE Do not overll the crankcase. Engine damage can result. Note: This machine is equipped with both an automated function for checking uid 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 uid 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. 1. Open the engine hood.
Engine Crankcase Breather Clean

SMCS Code: 1317-070-DJ 1. Open the engine hood.
Illustration 306 (1) (2) (3) (4) Outlet hose Hose clamp Breather O-ring seal
g01361732
212 Maintenance Section Engine Oil Sample - Obtain
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Illustration 307
g01316133
Illustration 309
g01316134
2. Remove the dipstick. Wipe the oil off the dipstick and reinsert the dipstick.
Note: Refer to Operation and Maintenance Manual, General Hazard Information for information on Containing Fluid Spillage. 4. Remove the oil ller plug in order to add oil, if necessary. See Operation and Maintenance Manual, Lubricant Viscosities. Note: If the oil is deteriorated or badly contaminated, change the oil regardless of the maintenance interval. 5. Clean the oil ller plug. Install the oil ller plug. 6. Close the engine hood.
i02980259
Illustration 308
g00104116
Engine Oil Sample - Obtain

SMCS Code: 1000-008; 1000; 1348-008; 1348-554-SM; 7542-008; 7542-554-OC, SM
3. Remove the dipstick and check the dipstick. The oil level should be between the H mark and the L mark. 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.
Illustration 310
g01507999
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213 Maintenance Section Engine Oil and Filter - Change
Obtain a sample of the engine oil from the engine oil sampling valve that is located inside an access door on the engine hood. Refer to Special Publication, SEBU6250, SOS Oil Analysis for information that pertains to obtaining a sample of the engine oil. Refer to Special Publication, PEHP6001, How To Take A Good Oil Sample for more information about obtaining a sample of the engine oil.
i02980394
Engine Oil and Filter - Change

SMCS Code: 1318-510
Illustration 312
g01508065
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. Note: If the sulfur content in the fuel is greater than 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.
2. Open the crankcase drain valve. Allow the oil to drain into a suitable container. Note: Discard any drained uids according to local regulations. 3. Close the drain valve. 4. Open the access door on the right side of the machine.
Illustration 313
g01508046
5. Remove the oil lter. See Operation and Maintenance Manual, Oil Filter - Inspect. Discard the used oil lter properly. 6. Clean the lter housing base. Make sure that all of the former lter gasket is removed.
Illustration 311
g00762020
7. Apply a thin coat of engine oil to the gasket of the new lter. 8. Install the new lter by hand. Instructions for the installation of the lter are printed on the side of each Caterpillar spin-on lter. For non-Caterpillar lters, refer to the installation instructions that are provided by the supplier of the lter.
1. The drain valve for the engine crankcase oil is located under the rear of the upper structure. Note: Refer to Operation and Maintenance Manual, General Hazard Information for information on Containing Fluid Spillage.
214 Maintenance Section Engine Valve Lash - Check
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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.
i03997106
Illustration 314 (1) Dipstick (2) Oil ller plug
g01316284
Film (Product Identication) Clean

SMCS Code: 7405-070; 7557-070
9. Remove oil ller plug (2). Fill the crankcase with new oil. See Operation and Maintenance Manual, Capacities (Rell) and Operation and Maintenance Manual, Lubricant Viscosities. Clean the oil ller plug and install the oil ller plug. NOTICE Do not under ll or overll 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.
Illustration 316
g02174985
Illustration 315
g00104116
11. Wait for 30 minutes in order to allow the oil to drain back into the crankcase. Check the oil level with dipstick (1). Maintain the oil between the H and L marks on the dipstick. If necessary, add oil. 12. Close the access door.
Illustration 317 Typical example of the Product Identication Films.
g02175297
Cleaning of the Films

Make sure that all of the product identication lms are legible. Make sure that the recommended procedures are used in order to clean the product identication lms. Ensure that all the product identication lms are not damaged or missing. Clean the product identication lms or replace the lms.
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215 Maintenance Section Final Drive Oil - Change
Hand Washing
Use a wet solution with no abrasive material that contains no solvents and no alcohol. Use a wet solution with a pH value between 3 and 11. Use a soft brush, a rag, or a sponge in order to clean the product identication lms. Avoid wearing down the surface of the product identication lms with unnecessary scrubbing. Ensure that the surface of the product identication lms is ushed with clean water and allow the product identication lms to air dry.
Power Washing
Power washing or washing with pressure may be used in order to clean product identication lms. However, aggressive washing can damage the product identication lms. Excessive pressure during power washing can damage the product identication lms by forcing water underneath the product identication lms. Water lessens the adhesion of the product identication lm to the product, allowing the product identication lm to lift or curl. These problems are magnied by wind. These problems are critical for the perforated lm on windows. To avoid lifting of the edge or other damage to the product identication lms, follow these important steps:
Illustration 318 (1) Oil level plug (2) Oil drain plug
g00822278
1. Position one nal drive so that oil drain plug (2) is at the bottom. Note: Refer to Operation and Maintenance Manual, General Hazard Information for information on Containing Fluid Spillage. 2. Remove drain plug (2) and level plug (1). Allow the oil to drain into a suitable container. 3. Clean the plugs and inspect the O-ring seals. If wear or damage is evident, replace the drain plug, the level plug, and/or the O-ring seals. 4. Install drain plug (2). 5. Fill the nal drive to the bottom of the opening on level plug (1). See Operation and Maintenance Manual, Lubricant Viscosities and Operation and Maintenance Manual, Capacities (Rell) . Note: If the oil lls slowly, the ll hole may be blocked by the planetary gear. Rotate the nal drive in order to move the planetary gear away from the ll hole. Note: Overlling the nal drive will cause the seals on the travel motor to allow hydraulic oil or water to enter the nal drive. The nal drive may become contaminated. 6. Install level plug (1). 7. Perform Step 1 to Step 6 on the other nal drive. Use a different container for the oil so that the oil samples from the nal drives will be separate. 8. Completely remove the oil that has spilled onto surfaces. 9. Start the engine and allow the nal drives to run through several cycles. 10. Stop the engine. Check the oil level.
Use a spray nozzle with a wide spray pattern. A maximum pressure of 83 bar (1200 psi) A maximum water temperature of 50 C (120 F) Hold the nozzle perpendicular to the product
identication lm at a minimum distance of 305 mm (12 inch). the edge of the product identication lm.
Do not direct a stream of water at a sharp angle to
i03908954
Final Drive Oil - Change

SMCS Code: 4050-044-FLV
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin.
216 Maintenance Section Final Drive Oil Level - Check
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11. Check the drained oil for metal chips or for particles. If there are any chips or particles, consult your Caterpillar dealer. 12. Properly dispose of the drained material. Obey local regulations for the disposal of the material.
i03914051
Note: Overlling the nal drive will cause the seals on the travel motor to allow hydraulic oil or water to enter the nal drive. The nal drive may become contaminated. 5. Clean oil level plug (1). Inspect the O-ring seal. Replace the O-ring seal if the O-ring seal is worn or damaged. 6. Install oil level plug (1). 7. Repeat the procedure for the other nal drive.
i03756611
Final Drive Oil Level - Check

Final Drive Oil Sample - Obtain

SMCS Code: 4011-008; 4050-008; 4050-SM; 7542-008
g00822278
1. Position one nal drive so that oil drain plug (2) is at the bottom. Note: Refer to Operation and Maintenance Manual, General Hazard Information for information on Containing Fluid Spillage. 2. Remove oil level plug (1). 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. See Operation and Maintenance, Lubricant Viscosities. Note: If the oil lls slowly, the ll hole may be blocked by the planetary gear. Rotate the nal drive in order to move the planetary gear away from the ll hole.
g00822278
1. Position the nal drive so that oil drain plug (2) is at the bottom. Note: Refer to Operation and Maintenance Manual, General Hazard Information for information on Containing Fluid Spillage. 2. Remove oil level plug (1). 3. Obtain a sample of the nal drive oil through the hole for the oil level plug. 4. Install oil level plug (1).
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217 Maintenance Section Fuel System - Prime
Refer to Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations, SOS Oil Analysis for more information on obtaining a sample of the nal drive oil. For additional information about taking an oil sample, refer to Special Publication, PEGJ0047, How To Take A Good Oil Sample.
i02980595
1. Open the engine hood.
Fuel System - Prime

SMCS Code: 1250-548
Personal injury or death may result from failure to adhere to the following procedures. Fuel leaked or spilled onto hot surfaces or electrical components can cause a re. Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system. Turn the disconnect switch OFF or disconnect the battery when changing fuel lters. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. NOTICE Do not loosen the fuel lines at the fuel manifold. The ttings may be damaged and/or a loss of priming pressure may occur when the fuel lines are loosened. Prime the fuel system in order to ll the fuel lter, and prime the fuel system in order to purge trapped air. The fuel system should be primed under the following conditions:
Illustration 321 (1) (2) (3) (4) (5) Air vent Air vent Secondary fuel lter Priming pump plunger Third fuel lter
g01508121
2. Loosen air vent (1) on the secondary fuel lter (3). 3. Turn the priming pump plunger (4) counterclockwise in order to unlock the priming pump plunger. Operate the priming pump plunger until a strong pressure is felt. This procedure will require considerable strokes. 4. Tighten air vent (1) when the fuel ow is free of air bubbles. 5. Loosen air vent (2) on the third fuel lter (5). 6. Operate priming pump plunger (4). 7. Tighten air vent (2) when the fuel ow is free of air bubbles. 8. Push in the priming pump plunger (4) and tighten the priming pump plunger by hand. NOTICE Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again. 9. Crank the engine. If the engine does not start or if the engine misres, additional priming is required. Also if the engine emits smoke, additional priming is required. 10. If the engine starts but the engine runs rough, continue to run the engine at low idle. Run the engine at low idle until the engine runs properly. 11. Check the fuel system for leaks. Stop the engine. 12. Close the engine hood.
The fuel tank is running low. The machine has been stored. The fuel lter is being replaced.
218 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace
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i03256754
Fuel System Primary Filter (Water Separator) Element Replace

SMCS Code: 1263-510-FQ Note: The replacement interval for this lter is recommended at every 250 service hours or monthly for machines that meet the following conditions for severe applications:
Poor fuel storage or poor refueling procedures Poor fuel cleanliness or low fuel quality Dusty conditions
Machines that are operated in normal applications should follow the replacement interval of every 500 service hours or 3 months.
Illustration 322 (1) (2) (3) (4) Drain valve Bowl Filter Filter base
g00752052
2. Turn drain valve (1) counterclockwise in order to open. The drain valve is located on the bottom of the water separator. Note: Refer to Operation and Maintenance Manual, General Hazard Information for information that pertains to containing uid spillage. 3. Drain the water and the sediment into a suitable container. Note: Dispose of used uids according to local regulations. 4. Close the drain valve (1). 5. Remove lter (3) from lter base (4). A lter wrench may be used to loosen the lter. 6. Remove lter (3) from bowl (2). Discard the used lter. Note: The water separator bowl is reusable. Do not discard the water separator bowl. 7. Clean the inside surfaces of lter base (4) and bowl (2).
Personal injury or death may result from failure to adhere to the following procedures. Fuel leaked or spilled onto hot surfaces or electrical components can cause a re. Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system. Turn the disconnect switch OFF or disconnect the battery when changing fuel lters. NOTICE Do not ll the fuel lters with fuel before installing the fuel lters. The fuel will not be ltered and could be contaminated. Contaminated fuel will cause accelerated wear to fuel system parts. 1. Open the access door on the left side of the machine.
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219 Maintenance Section Fuel System Secondary Filter - Replace
Instructions for the installation of the lter are printed on the side of each Caterpillar spin-on lter. For non-Caterpillar lters, refer to the installation instructions that are provided by the supplier of the lter. Note: Do not start the engine until all service to the fuel system is complete. For instructions about priming the fuel system, refer to Operation and Maintenance Manual, Fuel System - Prime. 13. Close the access door.
i03007496
Illustration 323 (2) (3) (5) (6) Bowl Filter Cap Seal
g00752055
Fuel System Secondary Filter Replace

SMCS Code: 1261-510 Note: The replacement interval for this lter is recommended at every 250 service hours or monthly for machines that meet the following conditions for severe applications:
8. Remove cap (5) from the bottom of new lter (3). Remove seal (6) from cap (5) and inspect the seal for damage. Replace the seal if the seal is damaged. 9. Lubricate the seal (6) for the bowl (2) with clean diesel fuel or lubricate the seal with motor oil. Place the seal in the groove in the bowl.
Poor fuel storage or poor refueling procedures Poor fuel cleanliness or low fuel quality Dusty conditions
Machines that are operated in normal applications should follow the replacement interval of every 500 service hours or 3 months.
Personal injury or death may result from failure to adhere to the following procedures. Fuel leaked or spilled onto hot surfaces or electrical components can cause a re. Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system. Turn the disconnect switch OFF or disconnect the battery when changing fuel lters. NOTICE Do not ll the fuel lters with fuel before installing the fuel lters. The fuel will not be ltered and could be contaminated. Contaminated fuel will cause accelerated wear to fuel system parts. 1. Open the engine hood.
Illustration 324 (2) Bowl (3) Filter (4) Filter base
g00752056
10. Install the bowl (2) onto the new lter by hand until the bowl is snug. Tighten the bowl to 7.3 Nm (5.0 lb ft) to approximately 1/6 of a turn. Do not use tools to tighten the bowl to the new lter. 11. Lubricate the seal on the new lter with clean diesel fuel or lubricate the seal with motor oil. 12. Install the new lter by hand.
220 Maintenance Section Fuel System Third Filter - Replace
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Note: Refer to Operation and Maintenance Manual, General Hazard Information for information on containing uid spillage.
i03007650
Fuel System Third Filter Replace

SMCS Code: 1261-510
Personal injury or death may result from failure to adhere to the following procedures. Fuel leaked or spilled onto hot surfaces or electrical components can cause a re. Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system. Turn the disconnect switch OFF or disconnect the battery when changing fuel lters. NOTICE Do not ll the fuel lters with fuel before installing the fuel lters. The fuel will not be ltered and could be contaminated. Contaminated fuel will cause accelerated wear to fuel system parts. 1. Open the engine hood. Note: Refer to Operation and Maintenance Manual, General Hazard Information for information on containing uid spillage.
Illustration 325
g01359809
2. Remove the lter. Note: Always discard used lters according to local regulations. 3. Clean the lter mounting base. Make sure that all of the used seal is removed. 4. Coat the seal of the new lter with clean diesel fuel. 5. Install the new fuel lter by hand. Instructions for the installation of the lter are printed on the side of each Caterpillar spin-on lter. For non-Caterpillar lters, refer to the installation instructions that are provided by the supplier of the lter. 6. Prime the fuel system. See Operation and Maintenance Manual, Fuel System - Prime for instructions. 7. Close the engine hood.
Illustration 326
g01361061
2. Remove the lter. Note: Always discard used lters according to local regulations.
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221 Maintenance Section Fuel System Water Separator - Drain
3. Clean the lter mounting base. Make sure that all of the used seal is removed. 4. Coat the seal of the new lter with clean diesel fuel. 5. Install the new fuel lter by hand. Instructions for the installation of the lter are printed on the side of each Caterpillar spin-on lter. For non-Caterpillar lters, refer to the installation instructions that are provided by the supplier of the lter. 6. Prime the fuel system. See Operation and Maintenance Manual, Fuel System - Prime for instructions. 7. Close the engine hood.
i02529331
4. Close drain valve (1). 5. Close the rear access door.

i02702814
Fuel Tank Cap and Strainer Clean

SMCS Code: 1273-070-STR
Fuel System Water Separator - Drain

SMCS Code: 1263 1. Open the rear access door on the left side of the machine. 2. Provide a suitable container for used uid. Note: Refer to Operation and Maintenance Manual, General Hazard Information for information on Containing Fluid Spillage.
Illustration 328
g01355638
1. Remove the fuel cap. 2. Inspect seal (2) for damage. Replace the seal, if necessary. 3. Remove cover (1) from the fuel cap.
Illustration 327 (1) Drain valve (2) Bowl
g00751973
3. Check bowl (2) in the bottom of the water separator. Open drain valve (1). Drain the water and sediment in the bowl. Note: Dispose of used uids according to local regulations.
Illustration 329
g00824196
Note: Refer to Operation and Maintenance Manual, General Hazard Information for information on Containing Fluid Spillage.
222 Maintenance Section Fuel Tank Water and Sediment - Drain
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4. Remove the strainer that is located in the ller opening. 5. Wash the strainer and the fuel tank cap in a clean, nonammable solvent. 6. Install a new cover (1). 7. Install the strainer into the ller opening. 8. Install the fuel tank cap.
i02709049
i02951573
Fuses - Replace
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. 1. Open the access door on the right side of the machine.
Illustration 331
g01466187
The fuse panel is located behind the left side access panel. Remove the cover in order to access the fuses. 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 electrical problem may exist. Contact your Caterpillar dealer. To replace a fuse, use the puller that is stored in the fuse panel. One fuse of 5 Amperes, three fuses of 10 Amperes, two fuses of 15 Amperes, two fuses of 20 Amperes, two fuses of 25 Amperes, and one fuse of 30 Amperes are contained in the fuse panel as spare fuses.
Illustration 330
g01043694
Note: Refer to Operation and Maintenance Manual, General Hazard Information for information on containing uid spillage. 2. Open the drain valve by turning the valve counterclockwise. Allow the water and the sediment to drain into a suitable container. Note: Dispose of drained uids according to local regulations. 3. Close the drain valve by turning the valve clockwise. 4. Close the access door.
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223 Maintenance Section Fuses - Replace
(11) Boom Light 10 Amp (12) Refueling Pump 10 Amp (13) Travel Alarm 5 Amp (14) Beacon 5 Amp (15) Air Conditioner 20 Amp (16) Horn 10 Amp (17) Machine Control Module 25 Amp (18) Cab Dome Light and Service Meter 10 Amp (19) Attachment Solenoid 10 Amp (20) Window Wiper And Window Washer 10 Amp (21) Switch Panel And Radio 5 Amp
Relays
Illustration 332
g01466189
The following list identies the circuits that are protected by each fuse. The amperage for each fuse is included with each circuit. (1) Engine Start Switch 10 Amp (2) Air Suspension Seat 10 Amp (3) 12 Volt Converter 10 Amp (4) Heater and Air Conditioner Blower Fan 10 Amp (5) Backup Switch 10 Amp (6) Seat Heater 5 Amp (7) Ignition Switch 10 Amp (8) Electronic Control Module 20 Amp (9) Product Link 5 Amp (10) Cab Light and Chassis Light 10 Amp
Illustration 333
g01466855
224 Maintenance Section High Intensity Discharge Lamp (HID) - Replace
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(22) Neutral Start Relay (23) Horn Relay (24) Chassis Lamp Relay (25) Auxiliary Relay (26) Boom Light Relay (27) Auxiliary Relay (28) Travel Alarm Relay (29) Cab Lamp Relay (30) Auxiliary Relay
i02245859
Note: On some HID lamps, the bulb is an integral part of the lens assembly. The bulb is not removed separately from the lens assembly. Replace the entire lens assembly on these HID lamps. 3. Remove the bulb from the HID lamp. 4. Install the replacement bulb in the HID lamp. If the bulb is an integral part of the lens assembly, install the replacement lens assembly in the HID lamp. Note: In order to avoid failure to the bulb that is premature, avoid touching the bulb's surface with your bare hands. Clean any ngerprints 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. 6. Reattach the electrical power to the HID lamp. 7. Check the HID lamp for proper operation. Note: Consult your Caterpillar dealer for additional information on HID lamps.
High Intensity Discharge Lamp (HID) - Replace (If Equipped)

SMCS Code: 1434-510
HID lamps operate at very high voltages. To avoid electrical shock and personal injury, disconnect power before servicing HID lamps.
i03789049
Hydraulic System Oil - Change

SMCS Code: 5056-044
HID bulbs become very hot during operation. Before servicing, remove power from lamp for at least ve minutes to ensure lamp is cool. NOTICE Although HID bulb materials may change over time, HID bulbs produced at the time of the printing of this manual contain mercury. When disposing of this component, or any waste that contains mercury, please use caution and comply with any applicable laws. 1. Remove the electrical power from the high intensity discharge lamp (HID). The electrical power must be removed from the HID lamp for at least ve minutes, in order to ensure that the bulb is cool. 2. Disassemble the housing for the HID lamp in order to have access to the bulb.
Cat HYDO Oil Change Interval

The standard Cat HYDO oil change interval is every 2000 service hours or 1 year. A 4000 service hour or 2 year maintenance interval for hydraulic oil (change) is available. The extended interval requires SOS monitoring of the hydraulic oil. The interval for SOS monitoring is every 500 hours. The maintenance interval for the hydraulic oil lter is not changed. Machines with hammers are not included in the 4000 service hour or 2 year 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 service hour or 2 year maintenance interval. Machines that are used in severe conditions must use the interval in the Maintenance Interval Schedule.
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225 Maintenance Section Hydraulic System Oil - Change
Cat HYDO Advanced 10 Oil Change Interval

The standard Cat HYDO Advanced 10 oil change interval is every 3000 service hours or 18 months. A 6000 service hour or 3 year maintenance interval for hydraulic oil (change) is available. The extended interval requires SOS monitoring of the hydraulic oil. The interval for SOS monitoring is every 500 hours. The maintenance interval for the hydraulic oil lter is not changed. Machines with hammers are not included in the 6000 service hour or 3 year 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 6000 service hour or 3 year maintenance interval. Machines that are used in severe conditions must use the interval in the Maintenance Interval Schedule.
2. Remove bolts (1), washers (2) and cover (3) from the top of the hydraulic tank.
Illustration 336
g01508983
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 ll/vent plug. 4. Relieve the internal pressure from the hydraulic tank by loosening the ll/vent plug. After the pressure is relieved, remove the ll/vent plug.
Procedure to Change the Hydraulic Oil
Illustration 334
g01244201
Illustration 337 The oil drain valve is located under the hydraulic tank.
g01244207
1. Park the machine on level ground. Lower the bucket to the ground so that the stick is vertical.
5. Remove the hydraulic tank access cover that is located under the upper structure. This will allow access to the drain valve.
Illustration 335
g01509276
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12. Clean plug (4) and install the plug. Tighten the plug to a torque of 75 5 Nm (55 4.8 lb ft). 13. Open the access door on the right side of the machine. 14. Clean the pump, the hydraulic lines, and the hydraulic tank.
Illustration 338 (4) Plug
g01508985
Note: Refer to Operation and Maintenance Manual, General Hazard Information for information that pertains to containing uid spillage. 6. Remove plug (4).
Illustration 340
g01509055
15. Remove the plug from the tube. Allow the oil to drain into a container. Note: Dispose of used lters and used uids according to local regulations. 16. Inspect the O-ring. Replace the O-ring if wear or damage is evident. 17. Clean the plug. Install the plug and the O-ring into the drain port.
Illustration 339 (5) Pipe Nipple (6) Hose (7) Drain plug
g01509004
7. Install a 3B-7271 Pipe Nipple (5) with hose (6) into the hole on the bottom of the hydraulic tank. 8. Loosen drain plug (7) in order to drain the oil. 9. Drain the oil into a suitable container. 10. After the oil has been drained, tighten drain plug (7) to a torque of 110 15 Nm (81 11 lb ft). 11. Remove Pipe Nipple (5) and hose (6).
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Illustration 342 (13) O-ring seal (14) O-ring seal
g01509135
21. Remove O-ring seal (13) from the screen. 22. Inspect O-ring seals (13) and (14). Replace the O-ring seals if wear or damage is evident. 23. Install O-ring seal (13) on screen (12). 24. Install screen (12) and spring (11). Then install cover (10), washers (9), and bolts (8).
Illustration 341 (8) Bolts (9) Washers (10) Cover (11) Spring (12) Screen
g01509134
Note: Make sure that the O-ring seals and the spring are properly positioned during installation. 25. Fill the hydraulic system oil tank. Refer to Operation and Maintenance Manual, Capacities (Rell).
18. Remove bolts (8), washers (9) and cover (10). Note: Dispose of used lters and used uids according to local regulations. Note: Do not allow spring (11) to fall back into the tank. 19. Remove spring (11) and screen (12). Note: Refer to Operation and Maintenance, General Hazard Information for information on containing uid spillage. 20. Wash the screen in a clean nonammable solvent. Allow the screen to dry. Inspect the screen. Replace the screen, if the screen is damaged.
Illustration 343
g01508983
26. Inspect the O-ring seal on the ller plug for damage. Replace the O-ring, if necessary. Clean the ller plug. Install the ller plug.
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NOTICE When the main hydraulic pump has been serviced or the hydraulic oil has been replaced, the air in the hydraulic system must be purged. Do not start the engine until the main hydraulic pump has been lled with oil. Operating the hydraulic pump without proper lubrication will damage the pump and other hydraulic components.
28. Start the engine. Operate the engine at idling speed for ve minutes.
Illustration 345
g01244201
29. Operate the joysticks 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.
Illustration 344 (15) Plug
g01509260
27. When the hydraulic oil has been replaced, the air must be removed from the hydraulic oil system. To remove the air from the hydraulic oil system, follow Step 27.a through Step 27.e. Reference: Refer to Testing and Adjusting, Main Hydraulic Pump Air Pressure - Purge in the service manual. a. While the engine is stopped, remove plug (15) from the top of the pump. Add hydraulic oil through the opening. b. Check the condition of seal. If the seal is damaged, replace the seal. c. After the pump has been lled with oil install the plug (15) to the original location. d. Start the engine. When the engine is at low idle, fully raise the boom. Hold the boom in this position. e. Stop the engine. Slowly lower the boom until the bucket is on the ground. This pressurizes the hydraulic tank. f. Slowly loosen the plug (15) until the hydraulic oil ows out of the opening. This indicates that the air has been released from the pump. g. Tighten the plug (15).
Illustration 346 (A) High temperature range (B) Low temperature range
g01510097
30. Maintain the oil level between the marks on the sight gauge in the appropriate temperature range. 31. Close the access door.
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229 Maintenance Section Hydraulic System Oil Filter (Case Drain) - Replace
i02915140
Hydraulic System Oil Filter (Case Drain) - Replace

SMCS Code: 5068-510; 5091-510
8. Open the access door on the right side of the machine.
Illustration 349 The case drain lter is located near the pilot oil lter.
g00760939
Illustration 347
g01244221
9. Clean the area in order to keep dirt out of the lter base. 10. Remove the used case drain lter from the lter base. Note: Used lters should always be disposed of according to local regulations. 11. Clean the lter base. Make sure that all of the old lter seal is removed.
1. Park the machine on level ground. Lower the work tool 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 pressure in the pilot lines. 5. Turn the engine start switch to the OFF position and return the hydraulic lockout control to the LOCKED position.
Illustration 350
g00101502
12. Apply clean hydraulic oil to the seal of the new case drain lter. 13. Install the new oil lter by hand.
Illustration 348
g01244225
6. Slowly loosen the ll/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 ll/vent plug.
Instructions for the installation of the lter are printed on the side of each Caterpillar spin-on lter. For non-Caterpillar lters, refer to the installation instructions that are provided by the supplier of the lter. 14. Start the engine and operate the machine slowly for 10 to 15 minutes. Move each cylinder evenly through several cycles.
230 Maintenance Section Hydraulic System Oil Filter (Pilot) - Replace
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4. Move the joysticks and the travel levers/pedals to the full stroke positions in order to relieve the pressure in the pilot lines. 5. Turn the engine start switch to the OFF position and return the hydraulic lockout control to the LOCKED position.
Illustration 351
g00760580
15. Return the machine to the position that is shown in Illustration 351. Check the machine for oil leaks. 16. Stop the engine. 17. Check the hydraulic oil level. Reference: For the correct procedure, refer to Operation and Maintenance Manual, Hydraulic System Oil Level - Check. 18. Close the access door.
i02709040
Illustration 353
g01244593
6. Slowly loosen the ll/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 ll/vent plug. 8. Open the access door on the right side of the machine.
Hydraulic System Oil Filter (Pilot) - Replace

SMCS Code: 5068-510; 5068-510-PS; 5092-510
Illustration 354
g00760988
Illustration 352
g01244221
9. Clean the area in order to keep dirt out of the lter base. 10. Remove the used pilot lter element from the lter base. Note: Used lters should always be disposed of according to local regulations. 11. Clean the lter base. Make sure that all of the old lter seal is removed.
1. Park the machine on level ground. Lower the work tool 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.
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231 Maintenance Section Hydraulic System Oil Filter (Return) - Replace
Illustration 355
g00101502
Illustration 356
g01509276
12. Apply clean hydraulic oil to the seal of the new pilot lter. 13. Install the new oil lter by hand. Instructions for the installation of the lter are printed on the side of each Caterpillar spin-on lter. For non-Caterpillar lters, refer to the installation instructions that are provided by the supplier of the lter. 14. Check the hydraulic oil level. Reference: For the correct procedure, refer to Operation and Maintenance Manual, Hydraulic System Oil Level - Check. 15. Close the access door.
i02982522
1. Remove bolts (1), washers (2) and plate (3) from the top of the hydraulic tank.
Illustration 357
g01508983
Hydraulic System Oil Filter (Return) - Replace

SMCS Code: 5068-510-RJ The return lter is a cartridge type of lter. By using a cartridge type of lter, the amount of foreign material that enters the hydraulic system is reduced when the lter element is replaced. Two different lters are available for the return lter. One lter is used for standard applications such as digging and normal use of a hammer. The second lter is used for an application such as demolishing a ceiling in a tunnel with a hammer. Note: If the message display shows that the hydraulic return lter 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 lter and replace the lter, if necessary.
2. Loosen the ller plug in order to relieve remaining hydraulic tank pressure. Tighten the ller plug after the hydraulic tank pressure is relieved. 3. Remove the lter cartridge. Perform Step 3.a through Step 3.f in order to remove the lter cartridge.
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Illustration 358 (4) (5) (6) (7) (8) Bolts Washers Cover Filter cartridge Plug
g00786177
Illustration 360
g00102214
d. Turn the lter cartridge counterclockwise by 180 degrees in order to align the projection of the lter cartridge with the notch of the lter case. Pull out the lter cartridge.
a. Remove bolts (4), washers (5), and cover (6). Note: Refer to Operation and Maintenance Manual, General Hazard Information for information on containing uid spillage. b. Remove plug (8) in order to release the pressure in lter cartridge (7). Note: When plug (8) is removed the oil level in the return lter drops to the level of the hydraulic tank.
Illustration 361 (10) O-ring
g00786186
e. Inspect the cover and O-ring (10). If either part is damaged, replace the part. f. Inspect the lter cartridge for debris and for damage. If necessary, replace the lter cartridge.
g00786183
Illustration 359 (7) Filter cartridge (9) Filter case (A) Guide
4. Remove the lter element. Perform Step 4.a through Step 4.f in order to remove the lter element.
c. Pull up the handle at the top of lter cartridge (7) until the lter cartridge contacts guide (A) on lter case (9).
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c. Hold the lter cartridge with one hand. Grasp the grip of plate (12) with your other hand. Lift plate (12) in order to separate plate (12) from the lter cartridge. d. Remove O-ring (16) from plate (8). e. Lift lter element (14) from shell (15). f. Pour the remaining oil into a suitable container. Note: Dispose of used oil according to local regulations.
Illustration 362 (8) Plug (11) O-ring (12) Plate
g00786193
g. Repeat Step 4.a through Step 4.f for the other lter groups. 5. Clean the shell of the lter cartridge. Perform Step 5.a through Step 5.d in order to clean the shell of the lter cartridge.
a. Make sure that plug (8) is removed. Make sure that all of O-ring (11) is removed from plate (12).
Illustration 365 Illustration 363 (12) Plate (13) Spiral retaining ring
g00945040
g00786209
(17) (18) (19) (20)
Slide plate Screws Port Blocking pads
b. Remove spiral retaining ring (13).
a. Turn shell (15) upside-down. b. Remove screws (18). c. Remove blocking pads (20) from slide plate (17). d. Wash the following parts in a clean nonammable solvent: plug (8), plate (12), spiral retaining ring (13), shell (15), and blocking pads (20). Dry the parts. 6. Install the lter elements. Perform Step 6.a through Step 6.k in order to install the lter elements. Note: Consult a Caterpillar dealer for the Service Kit that is needed to install the lter element and the lter cartridge. a. Apply spray type oil to the inside of shell (15) in order to prevent rust.
Illustration 364 (12) (14) (15) (16) Plate Filter element Shell O-ring
g00786204
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b. Apply grease to a new O-ring (16). c. Plate (12) will contact the inside of shell (15). Apply grease to this point. d. Apply grease to O-rings inside ports (19) at the bottom of shell (15). e. Install new blocking pads (20) with screws (18). Tighten the screws to a torque of 0.4 Nm (3.5 lb in). f. Apply spray type oil into the clearance between shell (15) and slide plate (17).
Illustration 367 (17) Slide plate (19) Port
g00786218
a. Check that ports (19) at the bottom of the lter case are closed. Note: If the ports are open, rotate slide plate (17) counterclockwise to the stopper in order to fully close the ports. When the ports are fully closed, any remaining oil in the lter case should be completely removed.
g00786216
Illustration 366 (12) Plate (15) Shell (B) Boss (C) Notch
g. Turn over shell (15). Apply grease to the two O-rings on new element (14). Install element (14) into shell (15). h. Move boss (B) in alignment with notch (C). Install plate (12) into shell (15). i. Install spiral retaining ring (13) into the groove in shell (15). j. Apply grease to new O-ring (11). Install O-ring (11) on plug (8). k. Install plug (8) into plate (12). 7. Install the lter cartridge. Perform Step 7.a through Step 7.e in order to install the lter cartridge.
Illustration 368 (17) Slide plate (19) Port
g00786236
b. Check that ports (19) of the lter cartridge are fully closed. Note: The lter cartridge cannot be installed unless the ports are fully closed. If the ports are open, rotate slide plate (17) counterclockwise to the stopper in order to fully close the ports.
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235 Maintenance Section Hydraulic System Oil Level - Check
i02982646
Hydraulic System Oil Level Check

SMCS Code: 5050-535 NOTICE Never remove the ll/vent plug from the hydraulic tank if the oil is hot. Air can enter the system and cause pump damage.
g00786241
Illustration 369 (21) O-rings
c. Check that O-rings (21) have been installed and that oil has been applied to O-rings (21).
Illustration 371
g01244615
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.
Illustration 370 (4) Bolts (5) Washers (6) Cover
g00786247
2. Open the access door on the right side of the machine.
d. Install the lter cartridge into the lter case. Turn the lter cartridge clockwise by 180 degrees and push down the lter cartridge when the lter cartridge contacts guide (A). e. Install cover (6), washers (5), and bolts (4). Tighten bolts (4) to a torque of 30 5 Nm (22 4 lb ft).
Illustration 372 (A) High temperature range (B) Low temperature range
g01510097
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. 4. Close the access door.
236 Maintenance Section Hydraulic System Oil Sample - Obtain
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The hydraulic oil sampling valve is near the pilot lter. Obtain a sample of the hydraulic oil from the hydraulic oil sampling valve. Refer to Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations, SOS Oil Analysis for information that pertains to obtaining a sample of the hydraulic oil. Refer to Special Publication, PEHP6001, How To Take A Good Oil Sample for more information about obtaining a sample of the hydraulic oil.
i02982716
Hydraulic Tank Screen - Clean

Illustration 373
g01244225
SMCS Code: 5056-070-Z3
Note: Refer to Operation and Maintenance Manual, General Hazard Information for information that pertains to Containing Fluid Spillage. Note: Perform Step 5 through Step 7 if the oil level is low. 5. Slowly loosen the ll/vent plug in order to relieve any pressure. Add oil, if necessary. 6. Check the O-ring seal of the ll/vent plug. Replace the O-ring seal if the O-ring seal is damaged. 7. Clean the ll/vent plug and install the ll/vent plug.
Illustration 375
i02252847 g01244221
Hydraulic System Oil Sample - Obtain

SMCS Code: 5050-008-OC; 5095-008; 5095-SM; 7542-008; 7542
1. Park the machine on level ground. Lower the bucket to the ground so that the stick is vertical.
Illustration 376 (1) Bolts (2) Washers (3) Cover Illustration 374
g00758661
g01509276
2. Remove bolts (1), washers (2) and cover (3) from the top of the hydraulic tank.
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237 Maintenance Section Hydraulic Tank Screen - Clean
5. Remove spring (11) and screen (12). Note: Refer to Operation and Maintenance, General Hazard Information for information on containing uid spillage. 6. Wash the screen in a clean nonammable solvent. Allow the screen to dry. Inspect the screen. Replace the screen, if the screen is damaged.
Illustration 377
g01508983
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 ll/vent plug.
Illustration 379 (13) O-ring seal (14) O-ring seal
g01509135
7. Remove O-ring seal (13) from the screen. 8. Inspect O-ring seals (13) and (14). Replace the O-ring seals if wear or damage is evident. 9. Install O-ring seal (13) on screen (12). 10. Install screen (8) and spring (7). Then install cover (6), washers (5), and bolts (4). Note: Make sure that the O-ring seals and the spring are properly positioned during installation.
Illustration 378 (8) Bolts (9) Washers (10) Cover (11) Spring (12) Screen
g01509134
4. Remove bolts (8), washers (9) and cover (10). Note: Dispose of used lters and used uids according to local regulations. Note: Do not allow spring (11) to fall back into the tank.
Illustration 380
g01508983
11. Inspect the O-ring seal on the ller plug for damage. Replace the O-ring, if necessary. Clean the ller plug. Install the ller plug. 12. Install cover (3) with bolts (1) and washers (2).
238 Maintenance Section Indicators and Gauges - Test
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i02116248
i02106227
Indicators and Gauges - Test

SMCS Code: 7450-081; 7490-081
Oil Filter - Inspect

SMCS Code: 1308-507; 5068-507
Inspect a Used Filter for Debris
Illustration 381
g01077750
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. 6. Stop the engine. 7. Make any repairs that are required before operating the machine.
Illustration 382 The element is shown with debris.
g00100013
Use a lter cutter to cut the lter element open. Spread apart the pleats and inspect the element for metal and for other debris. An excessive amount of debris in the lter element can indicate a possible failure. If metals are found in the lter 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. Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings, rod bearings, or turbocharger bearings. Small amounts of debris may be found in the lter 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 lter 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 unltered oil. The particles could enter the lubricating system and the particles could cause damage.
SEBU8266-06
239 Maintenance Section Radiator Core - Clean
i02983392
i02986894
Radiator Core - Clean

SMCS Code: 1353-070 1. Open the access door on the left side of the machine.
Receiver Dryer (Refrigerant) Replace

SMCS Code: 7322-510; 7322-710
Personal injury can result from contact with refrigerant. Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury. Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant. Always use precaution when a tting is removed. Slowly loosen the tting. If the system is still under pressure, release it slowly in a well ventilated area. Personal injury or death can result from inhaling refrigerant through a lit cigarette.
g01510396
Illustration 383
2. Remove four pins (1). 3. Remove screens (2). 4. Check all of the core ns for debris. 5. Remove dust and debris from all of the core ns and from the screens. Compressed air is preferred, but high pressure water or steam can be used to remove dust and general debris from a core. See Special Publication, SEBD0518, Know Your Cooling System for more detailed information about cleaning core ns. 6. Install screens (2) and pins (1). 7. Close the access door on the left side of the machine.
Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a ame contacting air conditioner refrigerant gas, can cause bodily harm or death. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Use a certied recovery and recycling cart to properly remove the refrigerant from the air conditioning system. NOTICE If the refrigerant system has been open to the outside air (without being plugged) for more than 30 minutes, the receiver-dryer must be replaced. Moisture will enter an open refrigerant system and cause corrosion which will lead to component failure. Refer to Service Manual, SENR5664, Air Conditioning and Heating System with R-134a Refrigerant for All Caterpillar Machines for the proper procedure to change the receiver-dryer assembly and for the procedure to reclaim the refrigerant gas. The receiver-dryer is located behind the access door at the base of the boom.
240 Maintenance Section Rollover Protective Structure (ROPS) - Inspect
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i02429589
Seat Belt - Inspect

SMCS Code: 7327-040 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.
Illustration 384
g01513382
i03737161
Rollover Protective Structure (ROPS) - Inspect

SMCS Code: 7323-040; 7325-040 S/N: TXN1-Up S/N: WLN1-Up S/N: XHR1-Up S/N: SSZ1-Up
g00932801
Check the seat belt mounting hardware (1) for wear or for damage. Replace any mounting hardware that is worn or damaged. Make sure that the mounting bolts are tight. Check buckle (2) for wear or for damage. If the buckle is worn or damaged, replace the seat belt. Inspect the seat belt (3) for webbing that is worn or frayed. Replace the seat belt if the seat belt is worn or frayed. Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware. Note: Within three years of the date of installation or within ve years of the date of manufacture, replace the seat belt. Replace the seat belt at the date which occurs rst. 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. If your machine is equipped with a seat belt extension, also perform this inspection procedure for the seat belt extension.
Illustration 385
g01961918
Consult your Caterpillar dealer for repair of any cracks in the ROPS. Inspect the ROPS for loose bolts or for damaged bolts. Replace any damaged bolts or missing bolts with original equipment parts only. Tighten the M24 bolt (1) to425 50 Nm (315 40 lb ft). Do not straighten the ROPS. Do not repair the ROPS by welding reinforcement plates to the ROPS. Consult your Caterpillar dealer for repair of any cracks in the ROPS.
SEBU8266-06
241 Maintenance Section Seat Belt - Replace
i02429594
Seat Belt - Replace

SMCS Code: 7327-510 Within three years of the date of installation or within ve years of the date of manufacture, replace the seat belt . Replace the seat belt at the date which occurs rst. 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.
Illustration 388
g00762001
The swing bearings are under the base of the boom.
Illustration 387 (1) Date (2) Date (3) Date (4) Date of installation (retractor) of installation (buckle) of manufacture (tag) (fully extended web) of manufacture (underside) (buckle)
g01152685
Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware.
Illustration 389
g00856187
If your machine is equipped with a seat belt extension, also perform this replacement procedure for the seat belt extension.
i02419506
Apply lubricant through the ttings until the lubricant overows the bearing seals.
i02983743
Swing Bearing - Lubricate

SMCS Code: 7063-086 Note: Caterpillar recommends the use of multipurpose lithium grease NLGI Grade 2 for lubricating the swing bearing. Refer to Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations for more information on multipurpose lithium grease. Note: Do not overgrease the swing bearings. Do not grease more than the recommended maintenance interval. Refer to Operation and Maintenance Manual, Maintenance Interval Schedule for more information. Wipe the ttings before you lubricate the swing bearings.
Swing Drive Oil - Change

SMCS Code: 5459-044
Illustration 390
g00760610
The oil drain is located under the center of the upper structure.
242 Maintenance Section Swing Drive Oil Level - Check
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Illustration 391
g00856223
Illustration 393
g01510533
Note: Refer to Operation and Maintenance Manual, General Hazard Information for information that pertains to Containing Fluid Spillage. 1. Remove drain plug (1). Allow the oil to drain into a suitable container. Note: Drained uids should always be disposed of according to local regulations. 2. Use a clean, nonammable solvent to clean the oil drain plug (1). Apply pipe sealant to the drain plug. 3. Install the oil drain plug (1).
5. Remove the dipstick (2). 6. Add the specied quantity of oil through the dipstick tube. See Operation and Maintenance, Capacities (Rell). 7. Check the oil level. Refer to Operation and Maintenance Manual, Swing Drive Oil Level Check for instructions. 8. 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. 9. Drained materials should always be disposed of according to local regulations.
i02986660
Swing Drive Oil Level - Check

Illustration 392
g01513166
4. Open the access door that is located at the base of the boom.
Illustration 394
g00761787
The dipstick for the swing drive oil is on the swing drive at the rear base of the boom.
SEBU8266-06
243 Maintenance Section Swing Drive Oil Sample - Obtain
3. Check the dipstick. Maintain the oil level between the tip of the dipstick and the mark on the dipstick. Add oil through the dipstick tube, if necessary. If the oil level is above the mark on the dipstick, then remove oil from the system. Restore the oil to the correct level position. 4. Insert the dipstick.
i02986679
Swing Drive Oil Sample Obtain

Illustration 395
g01513166
SMCS Code: 5459-008; 5459-008-OC; 5459-554-OC; 5459-OC; 7542-008

g01513243
g01513166
2. Remove the dipstick.
Illustration 397
g00418728
Illustration 399
g01513243
Note: Refer to Operation and Maintenance Manual, General Hazard Information for information that pertains to Containing Fluid Spillage.
2. Obtain an oil sample of the swing drive oil through the opening for the dipstick. Refer to Special Publication, SEBU6250, SOS Oil Analysis for information that pertains to obtaining an oil sample from the swing drive housing. Refer to Special Publication, PEHP6001, How To Take A Good Oil Sample for more information about obtaining an oil sample from the swing drive housing.
244 Maintenance Section Swing Gear - Lubricate
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i01963879
Swing Gear - Lubricate

SMCS Code: 7063-086 Note: Refer to Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations for more information on grease. 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 becomes 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.
Illustration 401 (1) (2) (3) (4) Bolts Washers Cover Gasket
g00688056
1. Remove bolts (1) and washers (2). Remove cover (3) and gasket (4).
Illustration 402 (3) Cover (4) Gasket Illustration 400

g00688052
g00688058
Remove the inspection cover that is located near the boom base. Inspect the grease.
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 oor of the pan. Refer to Operation and Maintenance Manual, Capacities (Rell) 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.
SEBU8266-06
245 Maintenance Section Track (Rubber) - Inspect/Replace
i01627666
Track (Rubber) Inspect/Replace (If Equipped)

SMCS Code: 4198-040; 4198-510 Note: Consult your Caterpillar dealer when the steel track is replaced with a rubber track. 1. Inspect the rubber track for damage. The rubber track can be repaired in certain cases. Repair the rubber track if the track is damaged in one of the following manners.
Illustration 403 (5) (6) (7) (8) Bolts Washers Cover Gasket
g00688063
The rubber track is cut by hard materials with

sharp edges. a quick turn.
4. Check for contamination and for discolored grease. 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 to allow the water to drain. When you reinstall cover (7), inspect gasket (8). Replace the gasket if damage is evident.
The rubber track has a shoe that is broken from The rubber track has a crack that is produced
by bending fatigue.
The rubber track has ne cracks in a shoe from

exposure to the sunlight. 2. In order to replace a damaged shoe with a new segment of shoe, perform the following procedures.
Illustration 404
g00101644
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. 8. Install gasket (4), cover (3), washers (2), and bolts (1).
Illustration 405
g00741518
a. Cut out area (A) of the damaged shoe. b. Remove four bolts (1). c. Remove the damaged shoe.
246 Maintenance Section Track Adjustment - Adjust
SEBU8266-06
d. Install new shoe (2). e. Fasten four bolts (1). f. Tighten bolts (1) to a torque of 175 40 Nm (129 29 lb ft).
i03091797
2. Stop with one track pin directly over the front carrier roller. Park the machine and turn off the engine.
Track Adjustment - Adjust

SMCS Code: 4170-025
Personal injury or death can result from grease under pressure. Grease coming out of the relief valve under pressure can penetrate the body causing injury or death. Do not watch the relief valve to see if grease is escaping. Watch the track or track adjustment cylinder to see if the track is being loosened. Loosen the relief valve one turn only. If track does not loosen, close the relief valve and 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 adjusted according to the current operating conditions. Keep the track as slack as possible if the soil is heavy.
Illustration 407
g00101752
3. Place a straight edge on top of the track grousers between the front carrier roller and the idler. The straight edge should be long enough to reach from the front carrier roller to the idler. Note: If your machine is equipped with three carrier rollers, place a straight edge on the tracks between the carrier rollers. The straight edge should be long enough to reach from one carrier roller to another carrier roller. 4. Measure the maximum amount of sag in the track. The sag is measured from the highest point of the track grouser to the bottom of the straight edge. A track that is properly adjusted will have a sag of 40.0 to 55.0 mm (1.57 to 2.17 inch). 5. If the track is too tight, or if the track is too loose, adjust the track tension according to the appropriate procedure below.
Measuring Track Tension

1. Operate the machine in the direction of the idlers.
Adjusting Track Tension

g01103855
g00270405
Typical example
The track adjuster is located on the track frame.
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247 Maintenance Section Track Adjustment - Inspect
Tightening the Track
4. Check the amount of sag. Adjust the track, as needed.

i01590290
Track Adjustment - Inspect

SMCS Code: 4170-040
Illustration 409 (1) Grease tting (2) Relief valve
g01091134
Wipe the tting before you add grease. 1. Add grease through grease tting (1) until the correct track tension is reached. 2. Operate the machine back and forth in order to equalize the pressure. 3. Check the amount of sag. Adjust the track, as needed.
g00824541
Illustration 411
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.
i02835935
Loosening the Track
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 lockout control to the UNLOCKED position.
g01091134
Illustration 410 (1) Grease tting (2) Relief valve
2. Raise the work tool in order to avoid any obstacles. Make sure that there is adequate overhead clearance.
1. Loosen relief valve (2) carefully until the track begins to loosen. One turn should be the maximum. 2. Tighten relief valve (2) to 34 5 Nm (25 4 lb ft) when the desired track tension is reached. 3. Operate the machine back and forth in order to equalize the pressure.
248 Maintenance Section Undercarriage - Check
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i01457296
Undercarriage - Check
SMCS Code: 4150-535
Illustration 412
g00560313
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 should sound.
Illustration 414
g00761955
1. Check the carrier rollers, the track rollers, and the idler wheels for possible leakage. 2. Check the surface of the track, the carrier rollers, the track rollers, the idler wheels, the track shoes, and the drive sprockets. Look for signs of wear and loose mounting bolts. 3. Listen for any abnormal noises while you are moving slowly in an open area. 4. If abnormal wear exists or abnormal noises or leaks are found, consult your Caterpillar dealer.
i02991295
Window Washer Reservoir Fill

Illustration 413
g01414105
SMCS Code: 7306-544-KE NOTICE When operating in freezing temperatures, use Caterpillar or any commercially available nonfreezing window washer solvent.
6. Push the alarm cancel switch. The travel alarm should shut off. 7. Stop the machine. Lower the work tool to the ground. Move the Hydraulic lockout control to the LOCKED position. Stop the engine.
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249 Maintenance Section Window Wiper - Inspect/Replace
i03910996
Windows - Clean
SMCS Code: 7310-070; 7340-070 Clean the outside of the windows from the ground, unless handholds are available.
Illustration 415
g01507235
1. Open the top access door on the right side of the machine.
g00566124
Cleaning Methods
Aircraft Window 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.
Illustration 416
g00688996
2. Remove the ller cap. 3. Fill the window washer reservoir with washer uid through the ller opening. 4. Install the ller cap. 5. Close the access door.
i01258249
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
Window Wiper Inspect/Replace

SMCS Code: 7305-040; 7305-510 Inspect the condition of the wiper blades. Replace the wiper blades if the wiper blades are worn or damaged or if streaking occurs.
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.
Polycarbonate Windows (If equipped)

Wash polycarbonate windows with a mild soap or detergent. Never use a cleaning solvent on polycarbonate windows. Wash polycarbonate windows with warm water and a soft sponge, or damp cloth. Never use a dry cloth or paper towels on polycarbonate windows.
250 Maintenance Section Windows - Clean
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Rinse the windows with a sufcient amount of clean water.

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MAINTENANCE INTERVALS

Operation and Maintenance Manual Excerpt

2010 Caterpillar All Rights Reserved

SEBU8266-06 October 2010

Operation and Maintenance Manual

188 Maintenance Section Maintenance Interval Schedule

Maintenance Interval Schedule

Every 10 Service Hours or Daily for First 100 Hours

Every 10 Service Hours or Daily

Every 10 Service Hours or Daily for Machines Used in Severe Applications

Every 100 Service Hours or 2 Weeks

Every 100 Service Hours of Continuous Hammer Use

Initial 250 Service Hours

Every 250 Service Hours

189 Maintenance Section Maintenance Interval Schedule

Every 250 Service Hours for Machines Used in Severe Applications

Every 2000 Service Hours or 1 Year

Every 250 Service Hours or Monthly

Every 3000 Service Hours or 18 Months

Every 6000 Service Hours or 3 Years

Every 500 Service Hours

Every 12 000 Service Hours or 6 Years

Every 500 Service Hours or 3 Months

Every 600 Service Hours of Continuous Hammer Use

Every 1000 Service Hours or 6 Months

190 Maintenance Section Air Conditioner/Cab Heater Filter (Recirculation) - Inspect/Replace

Air Conditioner/Cab Heater Filter (Recirculation) Inspect/Replace

The recirculation lter is on the left side of the operator seat.

A battery supplier An authorized battery collection facility Recycling facility

Battery Hold-Down - Tighten

191 Maintenance Section Battery or Battery Cable - Inspect/Replace

Battery or Battery Cable Inspect/Replace

Water Pump Belt, Fan Drive Belt, and Alternator Belt

192 Maintenance Section Blade Cutting Edges - Inspect/Replace

Illustration 255 (4) Nut (5) Adjusting bolt

Air Conditioner Belt (If Equipped)

Blade Cutting Edges Inspect/Replace (If Equipped)

193 Maintenance Section Blade Linkage - Lubricate

Wipe all ttings before you apply lubricant.

Boom and Stick Linkage Lubricate

Blade Linkage - Lubricate

194 Maintenance Section Boom and Stick Linkage - Lubricate

Standard Boom (If Equipped)

Illustration 260 Illustration 258

Illustration 261 Illustration 259

Offset Boom (If Equipped)

195 Maintenance Section Boom and Stick Linkage - Lubricate

Illustration 266 Illustration 263

Illustration 267 Illustration 264

7. Apply lubricant through tting (22) at the bucket cylinder head.

Boom Cylinder Guard

196 Maintenance Section Bucket Linkage - Inspect/Adjust

Bucket Linkage Inspect/Adjust

Illustration 270 Area for linkage adjustment

197 Maintenance Section Bucket Linkage - Lubricate

Bucket Linkage - Lubricate

Use a hammer and a punch from the retainer

Use a Pin-Master. Follow Step 1.a through Step

Bucket Tips - Inspect/Replace

198 Maintenance Section Bucket Tips - Inspect/Replace

Illustration 274 (6) Retainer assembly (7) Adapter

Illustration 276 (8) Pin