Beruflich Dokumente
Kultur Dokumente
2010 Caterpillar
All Rights Reserved
SEBU7342-08
May 2008
Operation and
Maintenance
Manual
320C Excavator
ANB1-Up (Machine)
MAB1-Up (Machine)
PAB1-Up (Machine)
AMC1-Up (Machine)
BDC1-Up (Machine)
CCD1-Up (Machine)
SBN1-Up (Machine)
BER1-Up (Machine)
RAW1-Up (Machine)
SAFETY.CAT.COM
152 SEBU7342-08
Maintenance Section
Maintenance Interval Schedule
Every 250 Service Hours Boom and Stick Linkage - Lubricate ................... 157
Engine Valve Lash - Check ................................. 178
Cooling System Coolant Sample (Level 1) - Final Drive Oil Level - Check .............................. 179
Obtain ............................................................... 168 Hydraulic System Oil Filter (Case Drain) -
Engine Oil Sample - Obtain ................................ 176 Replace ............................................................. 190
Final Drive Oil Sample - Obtain .......................... 179 Hydraulic System Oil Filter (Pilot) - Replace ....... 193
Hydraulic System Oil Filter (Return) - Replace ... 194
Every 250 Service Hours or Monthly Swing Drive Oil - Change ................................... 206
Belts - Inspect/Adjust/Replace ............................ 155
Condenser (Refrigerant) - Clean ........................ 165 Every 1000 Service Hours of Partial Hammer
Swing Bearing - Lubricate ................................... 206 Use (50% of Service Hours)
Swing Drive Oil Level - Check ............................ 208 Hydraulic System Oil - Change ........................... 186
Every 250 Service Hours of Partial Hammer Every 2000 Service Hours or 1 Year
Use (50% of Service Hours)
Final Drive Oil - Change ..................................... 178
Hydraulic System Oil Filter (Case Drain) - Hydraulic System Oil - Change ........................... 186
Replace ............................................................. 190 Receiver Dryer (Refrigerant) - Replace .............. 205
Hydraulic System Oil Filter (Pilot) - Replace ....... 193 Swing Gear - Lubricate ....................................... 209
Initial 500 Hours (for New Systems, Refilled Every 3 Years After Date of Installation or
Systems, and Converted Systems) Every 5 Years After Date of Manufacture
Cooling System Coolant Sample (Level 2) - Seat Belt - Replace ............................................. 206
Obtain ............................................................... 169
Every 6000 Service Hours or 3 Years
Every 500 Service Hours
Cooling System Coolant Extender (ELC) - Add .. 167
Hydraulic System Oil Sample - Obtain ............... 199
Swing Drive Oil Sample - Obtain ........................ 208 Every 12 000 Service Hours or 6 Years
Every 500 Service Hours or 3 Months Cooling System Coolant (ELC) - Change ........... 165
i01520787 4. After you clean the filter element, inspect the filter
element. If the filter element is damaged or badly
Air Conditioner/Cab Heater contaminated, use a new filter element. Make sure
Filter (Recirculation) - that the filter element is dry.
Inspect/Replace
i00934864
SMCS Code: 1054-040-A/C; 1054-510-A/C
Battery - Clean
NOTICE SMCS Code: 1401-070
An air recirculation filter element plugged with dust will
result in decreased performance and service life to the Clean the battery surface with a clean cloth. Keep the
air conditioner or cab heater. terminals clean and keep the terminals coated with
petroleum jelly. Install the post cover after you coat
To prevent decreased performance, clean the filter el- the terminal post with petroleum jelly.
ement, as required.
i00993589
Battery - Recycle
SMCS Code: 1401-561
A battery supplier
An authorized battery collection facility
Recycling facility
i00934872
g00685718
Illustration 287
i01913589 i03026885
10. Install the key and turn the battery disconnect The belt assembly for the tier II engines is for the following serial
numbers: (S/N: MAB1-UP; PAB1-UP; FBA1-UP; GAA1-UP;
switch to the ON position. MAA1-UP; PAA1-UP; RAW1-UP; SBN1-UP)
156 SEBU7342-08
Maintenance Section
Belts - Inspect/Adjust/Replace
g00688115
Illustration 291
The belt assembly for the tier I engines is for the following serial
numbers: (S/N: ANB1-UP; BCB1-UP; BDB1-UP; AMC1-UP;
BDC1-UP; CCD1-UP; ALF1-UP; AKH1-UP; BER1-UP)
(1) Mounting bolt
(2) Bracket bolt
(3) Adjusting bolt
SEBU7342-08 157
Maintenance Section
Boom Cylinder Head (Long Reach Configuration) - Lubricate
g00104278 g00685797
Illustration 293 Illustration 294
(4) Nut
(5) Adjusting bolt Apply lubricant through the fitting at the base of each
boom cylinder.
1. Apply approximately 100 N (22 lb) force midway
between the pulleys.
i01933858
4. When the adjustment is correct, tighten nut (4) to Note: Caterpillar recommends the use of 5%
a torque of 38 7 Nm (28 5 lb ft). molybdenum grease for lubricating the boom,
stick and bucket control linkage. Refer to Special
5. Check the deflection again. Publication, SEBU6250, Caterpillar Machine
Fluids Recommendations for more information on
Note: If a new belt is installed, check the belt molybdenum grease.
adjustment again after 30 minutes of engine
operation at the rated engine speed. Apply lubricant through all fittings after operation
under water.
6. Close the engine hood.
Wipe all fittings before you apply lubricant.
i01949843
g00685798 g00685800
Illustration 296 Illustration 298
2. The fittings are at the base of the boom. The 6. Apply lubricant through fitting (7) on the stick
fittings can be serviced from the platform on top cylinder rod, fitting (8) at the connection point of
of the storage box. To lubricate the lower boom the boom and of the stick, and fitting (9) at the
bearings, apply lubricant through fittings (1) and bucket cylinder head end.
(2).
i01933871
3. Apply lubricant through fittings (3) and (4) for the
boom cylinder rod. Boom, Stick and Bucket
4. Apply lubricant through fitting (5) for the stick Linkage (Long Reach
cylinder head.
Configuration) - Lubricate
Note: To ensure proper lubrication of the lower
SMCS Code: 6501-086; 6502-086; 6513-086
boom bearings and of the boom cylinder rod end
bearings, lubricant should be applied through fittings S/N: ANB1-Up
(1), (2), (3), and (4). Apply lubricant first when the
boom is raised and any attachment is suspended. Note: Caterpillar recommends the use of 5%
Then apply lubricant when the boom is lowered and molybdenum grease for lubricating the boom,
the attachment is rested on the ground with a slight stick and bucket control linkage. Refer to Special
downward pressure. Publication, SEBU6250, Caterpillar Machine
Fluids Recommendations for more information on
molybdenum grease.
g00685799
Illustration 297
g00685997
Illustration 299
SEBU7342-08 159
Maintenance Section
Bucket Linkage - Inspect/Adjust
1. Apply lubricant through fittings (1), (2), and (3) 7. Apply lubricant through fitting (13) for the stick
that are on the link. cylinder rod.
2. Apply lubricant through fittings (4), (5), and (6) 8. Apply lubricant through fitting (14) for the
that are on the bucket. connection of the boom and of the stick.
i02168785
Bucket Linkage -
Inspect/Adjust
SMCS Code: 6513-025; 6513-040
Illustration 300
g00685999 To avoid possible machine movement, move the
hydraulic lockout control to the locked position
3. The fittings are at the base of the boom. The and attach a Special Instruction, SEHS7332, Do
fittings can be serviced from the platform on top Not Operate or similar warning tag to the hy-
of the storage box. To lubricate the lower boom draulic lockout control.
bearings, apply lubricant through fittings (7) and
(8).
NOTICE
Improperly adjusted bucket clearance could cause
4. Apply lubricant through fittings (9) and (10) for the
galling on the contact surfaces of the bucket and
boom cylinder rod.
stick, resulting in excessive noise and/or damaged
O-ring seals.
5. Apply lubricant through fitting (11) for the stick
cylinder head.
g00101687
Illustration 302
(1) No gap
(2) Stick boss
(3) Bucket clearance
(4) Shims
(5) Pin
(6) Plate
(7) Bolts
(8) Washers
(9) Location
(10) Flange
(11) Bucket boss
g00110105
Illustration 301
The clearance of the bucket control linkage on 8. After installation, make sure that bucket clearance
this machine can be adjusted by shimming. If the (3) is still correct.
gap between the bucket and the stick becomes
excessive, adjust bucket clearance (3) to 0.5 to 1 mm
i01942324
(.02 to .04 inch).
g00102146
Illustration 303
Area for linkage adjustment
i02420545
The pin, when struck, can fly out and cause injury Illustration 306
g00590670
to nearby personnel.
(4) Back of Pin-Master
(5) Extractor
g00101352
Illustration 305
(1) Usable
(2) Replace this bucket tip.
(3) Overworn
Check the bucket tips for wear. If the bucket tip has a
hole, replace the bucket tip.
1. Remove the pin from the bucket tip. The pin can
be removed by one of the following methods.
g01194448
Illustration 307
Use a hammer and a punch from the retainer
side of the bucket to drive out the pin. (6) Retainer assembly
(7) Adapter
Use a Pin-Master. Follow Step 1.a through Step 2. Clean the adapter and the pin.
1.c for the procedure.
3. Fit retainer assembly (6) into the counterbore that
is in the side of adapter (7). Make sure that the
face of the retainer assembly with the marking
OUTSIDE is visible.
162 SEBU7342-08
Maintenance Section
Bucket Tips - Inspect/Replace
g00101359 g01209140
Illustration 308 Illustration 310
(4) Back of Pin-Master
4. Install the new bucket tip onto the adapter. (9) Pin holder
(10) Pin setter
Note: The bucket tips can be rotated by 180 degrees
in order to allow the tip to wear evenly. You may also b. Place the Pin-Master over the bucket tips so
move the tips from the outside teeth to the inside that the pin will fit into the counterbore of the
teeth. Check the tips often. If wear is present on the pin holder (9).
tips, rotate the tips. The outside teeth generate the
most wear. c. Strike the Pin-Master with a hammer at the
back of the tool (4) in order to insert the pin.
5. Drive the pin through the bucket tip. The pin can
be installed by using one of the following methods: d. Slide pin holder (9) away from the pin and
rotate the tool slightly in order to align pin setter
From the same side of the retainer, drive the pin (10) with the pin.
through the bucket tip, the retainer assembly,
and the adapter.
g01209159
Illustration 311
Final assembly of pin into bucket tip.
Side Cutters
g01092812
Illustration 314
g01092808
Illustration 312 Section B-B From Illustration 313
Bucket With Side Cutters (A) Side cutter
(A) Side cutters (C) Shear ledge on a side cutter
(D) Side plate on a bucket
(E) 0.0 mm (0.0 inch)
1. Remove the mounting bolts and the side cutters.
5. Make sure that there is not a gap between the
2. Clean the mounting surface of the side plate on side plate on the bucket and the shear ledge on
the bucket and of the side cutter. Remove any the side cutter.
burrs or protrusions on the mating surfaces.
6. Torque the mounting bolts to the correct
specification.
Side Protectors
Inspect the wear of the side protector. When too
much wear is present, replace the protector.
g01092810
Illustration 313
(A) Side cutter
1. Loosen bolt (1) and open filter cover (2) and air
filter (3).
g00851496
Illustration 316
(11) Side protector
(12) Pin
(13) Retainer
(14) side plate g00686273
Illustration 318
1. Hit pin (12) from the retainer side of the bucket (2) Filter cover
(3) Air filter
in order to remove side protector (11) from side
plate (14).
2. Remove air filter (3) from filter cover (2).
2. Clean side protector (11), pin (12), retainer (13)
and side plate (14) before installation. 3. Clean the air filter with a maximum of 200 kPa
(30 psi) pressure air.
3. Put retainer (13) in side plate (14).
4. After you clean the air filter, inspect the air filter.
4. Align two pin holes of the new protector and the If the air filter is damaged or badly contaminated,
side plate. Hit the pin from the side of the bucket use a new air filter.
without the retainer.
5. Install the air filter and the filter cover.
Note: If the pin and/or the retainer are worn, replace
the pin and/or the retainer. Note: Make sure that the arrow on top of the air filter
is facing forward.
i01520852
i01295288
Cab Air Filter (Fresh Air) - Circuit Breakers - Reset
Clean/Replace
SMCS Code: 1420-529
SMCS Code: 7342-070; 7342-510
g00686291
Illustration 319
g00686272
Illustration 317
(1) Bolt
(2) Filter cover
SEBU7342-08 165
Maintenance Section
Condenser (Refrigerant) - Clean
Typical example
i01041005
2. Inspect the condenser for debris. Clean the
Condenser (Refrigerant) - condenser, if necessary.
Clean 3. Use clean water to wash off all dust and dirt from
SMCS Code: 1805-070 the condenser.
NOTICE
Do not change the coolant until you read and under-
stand the cooling system information in Special Pub-
lication, SEBU6250, Caterpillar Machine Fluids Rec-
ommendations.
NOTICE
Mixing ELC with other products will reduce the effec-
tiveness of the coolant.
g00544378
This could result in damage to cooling system compo- Illustration 323
nents.
Note: Refer to Operation and Maintenance Manual,
If Caterpillar products are not available and com- General Hazard Information for information that
mercial products must be used, make sure they pertains to containing fluid spillage.
have passed the Caterpillar EC-1 specification for
pre-mixed or concentrate coolants and Caterpillar 4. Remove the access cover that is underneath the
Extender. radiator.
17. Install the reservoir cap. If Caterpillar products are not available and com-
mercial products must be used, make sure they
18. Close the engine hood and latch the engine hood. have passed the Caterpillar EC-1 specification for
Close the left access door. pre-mixed or concentrate coolants and Caterpillar
Extender.
i01901596
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g00811362
Illustration 326
A typical example is shown. Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
Obtain the sample of the coolant as close as possible suitable to collect and contain fluids on Caterpillar
to the recommended sampling interval. In order products.
to receive the full effect of SOS analysis, you
must establish a consistent trend of data. In order Dispose of all fluids according to local regulations and
to establish a pertinent history of data, perform mandates.
consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.
Keep the lids on empty sampling bottles until you Obtain the sample of the coolant as close as possible
are ready to collect the sample. to the recommended sampling interval. Supplies
for collecting samples can be obtained from your
Place the sample in the mailing tube immediately Caterpillar dealer.
after obtaining the sample in order to avoid
contamination. Refer to Operation and Maintenance Manual,
Cooling System Coolant Sample (Level 1) - Obtain
Never collect samples from expansion bottles. for the guidelines for proper sampling of the coolant.
Never collect samples from the drain for a system. Submit the sample for Level 2 analysis.
Submit the sample for Level 1 analysis. Reference: For additional information about coolant
analysis, refer to Special Publication, SEBU6250,
For additional information about coolant analysis, see Caterpillar Machine Fluids Recommendations or
Special Publication, SEBU6250, Caterpillar Machine consult your Caterpillar dealer.
Fluids Recommendations or consult your Caterpillar
dealer.
170 SEBU7342-08
Maintenance Section
Cooling System Coolant Level - Check
i02580035
i02530911
g00101416
Illustration 333
g01266486
Illustration 331 Note: Install the air cleaner cover properly. The
arrows must point upward.
3. Loosen the cover latches (2) and remove the air
cleaner cover. 9. Change the filter if any of the following conditions
occurs:
Pressurized air
Vacuum cleaning
SEBU7342-08 173
Maintenance Section
Engine Air Filter Secondary Element - Replace
Inspecting the Primary Air Filter Do not use paint, a waterproof cover, or plastic as a
protective covering for storage. An air flow restriction
Elements may result. To protect against dirt and damage, wrap
the primary air filter elements in Volatile Corrosion
Inhibited (VCI) paper.
Date of cleaning
Number of cleanings
Store the box in a dry location.
g00281693
Illustration 335
i01430699
Inspect the clean, dry primary air filter element. Use Engine Air Filter Secondary
a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air filter Element - Replace
element. Rotate the primary air filter element. Inspect
the primary air filter element for tears and/or holes. SMCS Code: 1054-510
Inspect the primary air filter element for light that may
show through the filter material. If it is necessary in NOTICE
order to confirm the result, compare the primary air Always replace the secondary filter element. Never at-
filter element to a new primary air filter element that tempt to reuse the secondary filter element by clean-
has the same part number. ing the element.
Do not use a primary air filter element that has any When the primary filter element is replaced, the sec-
tears and/or holes in the filter material. Do not use ondary filter element should be replaced.
a primary air filter element with damaged pleats,
gaskets or seals. Discard damaged primary air filter The secondary filter element should also be replaced
elements. if the air filter restriction warning appears on the mes-
sage display after the installation of a clean primary
Storing Primary Air Filter Elements filter element or if exhaust smoke is still black.
If a primary air filter element that passes inspection 1. Open the access door on the front left side of the
will not be used, the primary air filter element can machine.
be stored for future use.
2. See Operation and Maintenance Manual, Engine
Air Filter Primary Element - Clean/Replace.
Remove the air cleaner cover from the air cleaner
housing. Remove the primary filter element from
the air cleaner housing.
g00281694
Illustration 336
174 SEBU7342-08
Maintenance Section
Engine Crankcase Breather - Clean
g00101451
Illustration 337 i03026880
g00824182
g00824179 Illustration 339
Illustration 338
This tier I engine pertains to the following serial numbers: (S/N:
ANB1-UP; BDB1-UP; AMC1-UP; BCB1-UP; BDC1-UP; CCD1-UP;
2. Loosen hose clamp (2) and disconnect outlet hose ALF1-UP; AKH1-UP; BER1-UP)
(1) from breather (3).
SEBU7342-08 175
Maintenance Section
Engine Oil Level - Check
g00937619 g00824183
Illustration 340 Illustration 342
This tier II engine pertains to the following serial numbers: (S/N: This tier I engine pertains to the following serial numbers: (S/N:
MAB1-UP; PAB1-UP; FBA1-UP; GAA1-UP; MAA1-UP; PAA1-UP; ANB1-UP; BCB1-UP; BDB1-UP; AMC1-UP; BDC1-UP; CCD1-UP;
RAW1-UP; SBN1-UP) ALF1-UP; AKH1-UP; BER1-UP)
g00937631
Illustration 343
This tier II engine pertains to the following serial numbers: (S/N:
MAB1-UP; PAB1-UP; FBA1-UP; GAA1-UP; MAA1-UP; PAA1-UP;
g00824185 RAW1-UP; SBN1-UP)
Illustration 341
3. Remove the dipstick and check the dipstick. The Note: Refer to Operation and Maintenance Manual,
oil level should be between the H mark and the General Hazard Information for information on
L mark. Containing Fluid Spillage.
i01870159
g00101627
Illustration 345
i03024547
g00937651
Illustration 347
The crankcase drain valve for the tier II engine is located on the
following serial numbers: (S/N: MAB1-UP; PAB1-UP; FBA1-UP;
GAA1-UP; MAA1-UP; PAA1-UP; RAW1-UP; SBN1-UP)
SEBU7342-08 177
Maintenance Section
Engine Oil and Filter - Change
g00686496
Illustration 349
The tier I engine pertains to the following serial numbers: (S/N:
ANB1-UP; BCB1-UP; BDB1-UP; AMC1-UP; BDC1-UP; CCD1-UP;
ALF1-UP; AKH1-UP; BER1-UP)
(3) Dipstick
(4) Oil filler plug
g00686495
Illustration 348
(1) Drain valve
(2) Engine oil filter
12. Start the engine and allow the oil to warm. Check
the engine for leaks. Stop the engine.
178 SEBU7342-08
Maintenance Section
Engine Valve Lash - Check
g00104116 g00822278
Illustration 351 Illustration 352
(1) Oil level plug
13. Wait for 30 minutes in order to allow the oil to (2) Oil drain plug
drain back into the crankcase. Check the oil level
with dipstick (3). Maintain the oil between the H 1. Position one final drive so that oil drain plug (2) is
and L marks on the dipstick. If necessary, add oil. at the bottom.
14. Close the engine hood. Note: Refer to Operation and Maintenance Manual,
General Hazard Information for information on
Containing Fluid Spillage.
i01747875
Engine Valve Lash - Check 2. Remove drain plug (2) and level plug (1). Allow
the oil to drain into a suitable container.
SMCS Code: 1102-082; 1102-535; 1102; 1105-025;
1105-535; 1121-535; 1209-082; 1209-535; 1209; 3. Clean the plugs and inspect the O-ring seals. If
7527 wear or damage is evident, replace the drain plug,
the level plug, and/or the O-ring seals.
Refer to Engine Systems Operation/Testing and
Adjusting in order to perform the complete procedure 4. Install drain plug (2).
for the valve lash adjustment.
5. Fill the final drive to the bottom of the opening on
level plug (1). See Operation and Maintenance
i02580062 Manual, Lubricant Viscosities and Operation and
Maintenance Manual, Capacities (Refill) .
Final Drive Oil - Change
6. Install level plug (1).
SMCS Code: 4050-044-FLV
7. Perform Step 1 to Step 6 on the other final drive.
Use a different container for the oil so that the oil
samples from the final drives will be separate.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to 8. Completely remove the oil that has spilled onto
contact skin. surfaces.
i02580064 i02580071
Final Drive Oil Level - Check Final Drive Oil Sample - Obtain
SMCS Code: 4050-535-FLV SMCS Code: 4011-008; 4050-008; 4050-SM;
7542-008
g00822278
Illustration 353
g00822278
(1) Oil level plug Illustration 354
(2) Oil drain plug (1) Oil level plug
(2) Oil drain plug
1. Position one final drive so that oil drain plug (2) is
at the bottom. 1. Position the final drive so that oil drain plug (2) is
at the bottom.
Note: Refer to Operation and Maintenance Manual,
General Hazard Information for information on Note: Refer to Operation and Maintenance Manual,
Containing Fluid Spillage. General Hazard Information for information on
Containing Fluid Spillage.
2. Remove oil level plug (1).
2. Remove oil level plug (1).
3. Check the oil level. The oil should be near the
bottom of the level plug opening. 3. Obtain a sample of the final drive oil through the
hole for the oil level plug.
4. Add oil through the level plug opening, if
necessary. See Operation and Maintenance, 4. Install oil level plug (1).
Lubricant Viscosities.
Refer to Special Publication, SEBU6250, Caterpillar
Note: Overfilling the final drive will cause the seals on Machine Fluids Recommendations, SOS Oil
the travel motor to allow hydraulic oil or water to enter Analysis for more information on obtaining a sample
the final drive. This may contaminate the final drive. of the final drive oil. For additional information about
taking an oil sample, refer to Special Publication,
5. Clean oil level plug (1). Inspect the O-ring seal. PEHP6001, How To Take A Good Oil Sample.
Replace the O-ring seal if the O-ring seal is worn
or damaged.
i01516680
Check the inlet screen of water separator. If foreign 6. Replace the inlet screen into the water separator
particles are found, clean the inlet screen. Use Step 1 base.
through Step 8 in order to clean the fuel inlet screen.
7. Replace filter case (3) and screen holder (4).
Tighten ring nut (2).
i02582070
NOTICE
g00666109 Turn the disconnect switch OFF or disconnect the bat-
Illustration 355
tery when changing fuel filters.
(1) Drain valve
(2) Ring nut
(3) Filter case Do not fill fuel filters with fuel before installing them.
(4) Screen holder Contaminated fuel will cause accelerated wear to fuel
(5) Inlet screen systems parts.
(6) O-ring
1. Loosen drain valve (1) of the water separator and 1. Open the engine hood.
drain the water into a suitable container.
Note: Refer to Operation and Maintenance Manual,
Note: Refer to Operation and Maintenance Manual, General Hazard Information for information on
General Hazard Information for information on containing fluid spillage.
containing fluid spillage.
5. Install the new fuel filter hand tight until the seal of
the fuel filter contacts the filter mounting base.
i02582065 4. Tighten air vent (1) when the fuel flow is free of
air bubbles.
Fuel System - Prime
5. Loosen air vent (3) on the fuel injector pump.
SMCS Code: 1250-548
6. Operate priming pump plunger (2). Allow the fuel
to flow until the fuel is free of air bubbles.
Personal injury or death may result from failure to 7. Push the plunger inward and rotate the plunger
adhere to the following procedures. clockwise. This motion will lock the plunger in
place.
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. 8. Tighten vent plug (3) on the fuel injection pump.
Clean up all leaked or spilled fuel. Do not smoke Note: Lock the priming pump plunger before vent
while working on the fuel system. plug (3) is tightened. Pressure in the fuel system
could make locking the plunger in place difficult.
Turn the disconnect switch OFF or disconnect the
battery when changing fuel filters. i01430725
NOTICE
Do not fill the fuel filters with fuel before installing the
fuel filters. The fuel will not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
ated wear to fuel system parts.
g00686991
Illustration 358
i03024550
Make sure that you lock the fuel tank cap after the
refueling is complete.
i01835389
Illustration 362
g00824198
Fuses - Replace
(S/N: ANB1-3815)
(S/N: MAB1-403) SMCS Code: 1417-510
(S/N: PAB1-1660)
(S/N: AMC1-3757)
(S/N: BDC1-UP)
(S/N: CCD1-UP)
(S/N: BER1-UP)
(S/N: RAW1-UP)
(S/N: SBN1-UP)
g00101721
Illustration 364
g01043694
Illustration 363
(S/N: AMC3758-UP)
(S/N: ANB3816-UP)
(S/N: MAB404-UP)
(S/N: PAB1661-UP)
To replace a fuse, use the puller that is stored in the Horn (9) 10 Amp
fuse panel. Three fuses of 5 Amperes, five fuses of
10 Amperes, two fuses of 15 Amperes, and one fuse Cab Light (If Equipped) (10) 10 Amp
of 30 Amperes are contained in the fuse panel as
spare fuses. Cab Dome Light and Radio Memory (11) 10 Amp
The following list identifies the circuits that are Engine Start Switch (12) 10 Amp
protected by each fuse. The amperage for each fuse
is included with each circuit. Engine Controller or Pump Controller (13) 10
Amp
Alternator Regulator (32) 5 Amp Diesel engine oils (Heavy Duty) with a minimum
zinc content of 900 ppm can be used. Acceptable
Cab Fan (If Equipped) (33) 5 Amp commercial oils are identified by the American
Petroleum Institute trademark (API) . Refer to the list
Auxiliary Circuit (Attachment) (34) 10 Amp that follows for acceptable types of hydraulic oils.
Cat HYDO
TDTO
TDTO (TMS)
DEO
Biodegradable Hydraulic Oil (HEES)
SEBU7342-08 187
Maintenance Section
Hydraulic System Oil - Change
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Illustration 370
The oil drain valve is located under the hydraulic tank.
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Illustration 371
(4) Plug
15. Remove the plug from the tube. Allow the oil to
drain into a container.
17. Clean the plug. Install the plug and the O-ring into
the drain port.
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Illustration 372
(5) Pipe Nipple
(6) Hose
(7) Drain plug
13. Open the access door on the right side of the Note: Dispose of used filters and used fluids
machine. according to local regulations.
14. Clean the pump, the hydraulic lines, and the Note: Do not allow spring (11) to fall back into the
hydraulic tank. tank.
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Illustration 373
SEBU7342-08 189
Maintenance Section
Hydraulic System Oil - Change
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Illustration 375 Illustration 377
(13) O-ring seal
(14) O-ring seal 27. Remove the pressure cap.
21. Remove O-ring seal (13) from the screen. 28. Inspect the pressure cap. Clean the pressure cap.
Replace the pressure cap if damage is evident.
22. Inspect O-ring seals (13) and (14). Replace the
O-ring seals if wear or damage is evident. 29. Replace the pressure cap.
Note: Make sure that the O-ring seals and the spring
are properly positioned during installation.
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Illustration 378
(15) Drain hose
(16) Connector
(17) Seal
(18) Negative flow control hose
30. When the hydraulic oil has been replaced, the air
must be removed from the hydraulic oil system.
Illustration 376
g00687312 To remove the air from the hydraulic oil system,
follow Step 30.a through Step 30.g.
26. Inspect the O-ring seal on the filler plug for
damage. Replace the O-ring, if necessary. Clean a. While the engine is stopped, remove drain
the filler plug. Install the filler plug. hose (15), connector (16) and seal (17) from
the top of the pump. Add hydraulic oil through
the opening.
c. After the pump has been filled with oil, install 32. Operate the joysticks in order to circulate the
drain hose (15), connector (16) and seal (17) to hydraulic oil. Lower the bucket to the ground so
the original locations. that the stick is vertical to the ground. Stop the
engine.
d. Start the engine. When the engine is at low
idle, fully raise the boom. Hold the boom in this
position.
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Illustration 381
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Illustration 382
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Illustration 380
SEBU7342-08 191
Maintenance Section
Hydraulic System Oil Filter (Case Drain) - Replace
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Illustration 383 Illustration 385
2. Move the lever for the hydraulic lockout control to 8. Open the access door on the right side of the
the UNLOCKED position. machine.
g00687481
Illustration 386
The case drain filter is located near the pilot oil filter.
10. Remove the used case drain filter from the filter
mounting base.
6. Slowly loosen the fill/vent plug on top of the Note: Used filters should always be disposed of
hydraulic tank in order to relieve the internal according to local regulations.
pressure of the hydraulic tank.
11. Clean the filter mounting base. Make sure that all
7. After the pressure is relieved, tighten the fill/vent of the old filter seal is removed.
plug.
192 SEBU7342-08
Maintenance Section
Hydraulic System Oil Filter (Case Drain) - Replace
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Illustration 387 Illustration 388
(A) High temperature range
12. Apply clean hydraulic oil to the seal of the new (B) Low temperature range
case drain filter.
18. Maintain the oil level in the low temperature range
13. Install the new filter hand tight until the seal of the for a cold machine. Maintain the oil level in the
filter contacts the filter mounting base. Note the high temperature range for a machine that is at a
position of the index marks on the filter in relation normal operating temperature.
to a fixed point on the filter mounting base.
15. Start the engine and operate the machine slowly 19. Slowly loosen the fill/vent plug in order to relieve
for 10 to 15 minutes. Move each cylinder evenly any pressure. Remove the fill/vent plug in order
through several cycles. to add oil, if necessary.
16. Return the machine to the position that is shown 20. Clean the fill/vent plug. Install the fill/vent plug.
in Illustration 382. Check the machine for oil leaks.
21. Close the access door.
17. Stop the engine.
SEBU7342-08 193
Maintenance Section
Hydraulic System Oil Filter (Pilot) - Replace
i02232803
g00687449
Illustration 392
Illustration 390
g00101435 7. After the pressure is relieved, tighten the fill/vent
plug.
1. Park the machine on level ground. Lower the
bucket to the ground so that the stick is vertical.
g00101497
Illustration 393
Illustration 391
g00811329 8. Open the access door on the right side of the
machine.
2. Move the lever for the hydraulic lockout control to
the UNLOCKED position.
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Illustration 394
10. Remove the used pilot filter element from the filter
mounting base.
11. Clean the filter mounting base. Make sure that all
of the old filter seal is removed.
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Illustration 396
(A) High temperature range
(B) Low temperature range
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Illustration 395
13. Install the new filter hand tight until the seal of the
filter contacts the filter mounting base. Note the
position of the index marks on the filter in relation
to a fixed point on the filter mounting base.
Two different filters are available for the return filter. a. Remove bolts (1), washers (2), and cover (3).
One filter is used for standard applications such as
digging and normal use of a hammer. The second Note: Refer to Operation and Maintenance Manual,
filter is used for an application such as demolishing a General Hazard Information for information on
ceiling in a tunnel with a hammer. containing fluid spillage.
Note: If the message display shows that the hydraulic b. Remove plug (4) in order to release the
return filter is plugged, turn off the machine. After you pressure in filter cartridge (5).
make sure that the warning has disappeared, start
the machine and run the machine on level ground for Note: When plug (4) is removed the oil level in the
approximately 10 minutes. If the warning still appears return filter drops to the level of the hydraulic tank.
in the message display, inspect the filter and replace
the filter, if necessary.
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Illustration 400
(5) Filter cartridge
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Illustration 398 (6) Filter case
(A) Guide
1. Loosen the fill/vent plug in order to relieve the
hydraulic tank pressure. Tighten the fill/vent plug c. Pull up the handle at the top of filter cartridge
after the hydraulic tank pressure is relieved. (5) until the filter cartridge contacts guide (A)
on filter case (6).
Note: The return filter cartridge is located behind the
fill/vent plug.
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Illustration 401
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Illustration 402 Illustration 404
(7) O-ring (8) Plate
(9) Spiral retaining ring
e. Inspect the cover and O-ring (7). If either part
is damaged, replace the part. b. Remove spiral retaining ring (9).
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Illustration 405
(8) Plate
(10) Shell
(11) O-ring
(12) Filter element
a. Make sure that plug (4) is removed. Make sure e. Lift filter element (12) from shell (10).
that all of O-ring (18) is removed from plate (8).
f. Pour the remaining oil into a suitable container.
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Illustration 406 Illustration 407
(13) Slide plate (8) Plate
(14) Pads (10) Shell
(15) Screws (16) Boss
(19) Port (17) Notch
a. Turn shell (10) upside-down. g. Turn over shell (10). Apply grease to the two
O-rings on new element (12). Install element
b. Remove screws (15). (12) into shell (10).
c. Remove Pads (14) from slide plate (13). h. Move boss (16) in alignment with notch (17).
Install plate (8) into shell (10).
d. Wash the following parts in a clean
nonflammable solvent: plug (4), plate (8), spiral i. Install spiral retaining ring (9) into the groove
retaining ring (9), shell (10), and Pads (14). Dry in shell (10).
the parts.
j. Apply grease to new O-ring (18). Install O-ring
5. Install the filter elements. Perform Step 5.a through (18) on plug (4).
Step 5.k in order to install the filter elements.
k. Install plug (4) into plate (8).
Note: Consult a Caterpillar dealer for the Service Kit
that is needed to install the filter element and the 6. Install the filter cartridge. Perform Step 6.a through
filter cartridge. Step 6.e in order to install the filter cartridge.
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Illustration 411
(1) Bolts
NOTICE
Never remove the fill/vent plug from the hydraulic tank
if the oil is hot.
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Illustration 410
(F) O-rings
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Illustration 412
The hydraulic oil tank is on the right side of the machine.
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g00687286
Illustration 414 Illustration 416
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3. For a cold machine, maintain the hydraulic oil level The hydraulic oil sampling valve is near the pilot filter.
in the low temperature range. For a machine that Obtain a sample of the hydraulic oil from the hydraulic
is at normal operating temperature, maintain the oil sampling valve that is located on the hydraulic
hydraulic oil level in the high temperature range. oil filter housing. Refer to Special Publication,
SEBU6250, SOS Oil Analysis for information that
4. Close the access door. pertains to obtaining a sample of the hydraulic oil.
Refer to Special Publication, PEHP6001, How To
Take A Good Oil Sample for more information about
obtaining a sample of the hydraulic oil.
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Illustration 415
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g00687312
Illustration 419
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Illustration 418 Illustration 420
(1) Bolts (4) Bolts
(2) Washers (5) Washers
(3) Cover (6) Cover
(7) Spring
2. Remove bolts (1), washers (2) and cover (3) from (8) Screen
the top of the hydraulic tank.
5. Remove bolts (4), washers (5) and cover (6).
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Illustration 421
(9) O-ring seal g00687578
(10) O-ring seal Illustration 422
8. Remove O-ring seal (9) from screen (12). 1. Look for broken lenses on the gauges, broken
indicator lights, broken switches, and other broken
9. Inspect O-ring seals (9) and (10). Replace the components in the cab.
O-ring seals if wear or damage is evident.
2. Start the engine.
10. Install O-ring seal (9) on screen (12).
3. Look for inoperative gauges.
11. Install screen (8) and spring (7). Then install cover
(6), washers (5), and bolts (4). 4. Turn on all machine lights. Check for proper
operation.
Note: Make sure that the O-ring seals and the spring
are properly positioned during installation. 5. Move the machine forward. Release the travel
levers and the travel pedals. The machine should
12. Inspect the O-ring seal on the filler plug for stop.
damage. Replace the O-ring, if necessary. Clean
the filler plug. Install the filler plug. 6. Stop the engine.
13. Install cover (3) with bolts (1) and washers (2). 7. Make any repairs that are required before
operating the machine.
202 SEBU7342-08
Maintenance Section
Oil Filter - Inspect
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g00100013
Illustration 423
The element is shown with debris.
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Illustration 425
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Illustration 426 Illustration 428
(3) Latch
4. Remove dust and debris from the radiator fins and
from screen (2). 3. Raise latch (3) and rotate the latch by 1/2 turn.
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Illustration 427
(1) Wing bolts
(2) Screen
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Illustration 430 Illustration 431
(1) Engine hood
7. Remove dust and debris from the radiator fins and (2) Access door
from screens (2). (3) Wing bolts
(4) Screen
Compressed air is preferred, but high pressure
water or steam can be used to remove dust and 2. Loosen wing bolts (3) and remove screens (4)
general debris from a radiator. Clean the radiator from the radiator.
according to the condition of the radiator.
10. Close the engine hood and close the access door.
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g00937672
Illustration 432
Radiator, Aftercooler and Oil
3. Check the fins for debris.
Cooler Cores - Clean
SMCS Code: 1063-070-KO; 1353-070-KO;
1374-070-KO
S/N: MAB1-Up
S/N: PAB1-Up
S/N: SBN1-Up
S/N: RAW1-Up
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Illustration 433
i02723802 i02429589
Inhaling air conditioner refrigerant gas through a Check the seat belt mounting hardware (1) for wear
lit cigarette or other smoking method or inhaling or for damage. Replace any mounting hardware that
fumes released from a flame contacting air con- is worn or damaged. Make sure that the mounting
ditioner refrigerant gas, can cause bodily harm or bolts are tight.
death.
Check buckle (2) for wear or for damage. If the buckle
Do not smoke when servicing air conditioners or is worn or damaged, replace the seat belt.
wherever refrigerant gas may be present.
Inspect the seat belt (3) for webbing that is worn or
Use a certified recovery and recycling cart to prop- frayed. Replace the seat belt if the seat belt is worn
erly remove the refrigerant from the air condition- or frayed.
ing system.
Consult your Caterpillar dealer for the replacement of
the seat belt and the mounting hardware.
206 SEBU7342-08
Maintenance Section
Seat Belt - Replace
Note: Within three years of the date of installation or Note: Do not overgrease the swing bearings. Do not
within five years of the date of manufacture, replace grease more than the recommended maintenance
the seat belt. Replace the seat belt at the date which interval. Refer to Operation and Maintenance
occurs first. A date label for determining the age of Manual, Maintenance Interval Schedule for more
the seat belt is attached to the seat belt, the seat belt information.
buckle, and the seat belt retractor.
Wipe the fittings before you lubricate the swing
If your machine is equipped with a seat belt bearing.
extension, also perform this inspection procedure for
the seat belt extension.
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g01152685
Illustration 435
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Date of manufacture (tag) (fully extended web)
(4) Date of manufacture (underside) (buckle)
g00687903
Illustration 437
Consult your Caterpillar dealer for the replacement of
the seat belt and the mounting hardware. Apply lubricant through the fittings until the lubricant
overflows the bearing seals.
If your machine is equipped with a seat belt
extension, also perform this replacement procedure
for the seat belt extension. i02582097
Note: Refer to Special Publication, SEBU6250, Hot oil and hot components can cause personal
Caterpillar Machine Fluids Recommendations for injury. Do not allow hot oil or hot components to
more information on grease. contact skin.
SEBU7342-08 207
Maintenance Section
Swing Drive Oil - Change
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Illustration 438 Illustration 440
The oil drain hose is under the center of the upper 3. Tighten the drain valve. Hook the drain hose (2)
structure. to the holder (1). Make sure that the end of the
hose is facing upward.
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Illustration 439
g00687983
Illustration 441
Note: Refer to Operation and Maintenance Manual,
General Hazard Information for information that 4. Remove dipstick (4).
pertains to Containing Fluid Spillage.
5. Add the specified quantity of oil through the
1. Remove drain hose (2) from holder (1) on the dipstick tube. See Operation and Maintenance,
upper frame. Face the end of the hose toward Capacities (Refill).
the container.
6. Check the oil level. Refer to Operation and
2. Use a universal joint with a socket extension to Maintenance Manual, Swing Drive Oil Level -
loosen the drain valve in hole (3). Drain the oil into Check for the procedure.
a suitable container.
7. Check the oil that has been drained for metal chips
Note: Drained fluids should always be disposed of or metal particles. Consult your Caterpillar dealer
according to local regulations. if any metal chips or metal particles are found.
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Illustration 444
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g00684917
Illustration 445
SEBU7342-08 209
Maintenance Section
Swing Gear - Lubricate
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NOTICE
1. Remove bolts (1) and washers (2). Remove cover
Improper lubrication can cause damage to machine
(3) and gasket (4).
components.
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Illustration 448
(3) Cover
(4) Gasket
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g00101644
Illustration 450
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Illustration 452
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Illustration 454
3. Place a straight edge on top of the track grousers
(1) Grease fitting
between the front carrier roller and the idler. The (2) Relief valve
straight edge should be long enough to reach from
the front carrier roller to the idler. Wipe the fitting before you add grease.
4. Measure the maximum amount of sag in the track. 1. Add grease through grease fitting (1) until the
The sag is measured from the highest point of the correct track tension is reached.
track grouser to the bottom of the straight edge. A
track that is properly adjusted will have a sag of 2. Operate the machine back and forth in order to
40.0 to 55.0 mm (1.57 to 2.17 inch). equalize the pressure.
5. If the track is too tight, or if the track is too 3. Check the amount of sag. Adjust the track, as
loose, adjust the track tension according to the needed.
appropriate procedure below.
Loosening the Track
Adjusting Track Tension
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Illustration 455
g00270405
Illustration 453 (1) Grease fitting
Typical example (2) Relief valve
The track adjuster is located on the track frame. 1. Loosen relief valve (2) carefully until the track
begins to loosen. One turn should be the
maximum.
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g00560313
Illustration 457
i02252128
1. Start the engine. Move the hydraulic lockout 6. Push the alarm cancel switch. The travel alarm
control to the UNLOCKED position. should shut off.
2. Raise the work tools in order to avoid any 7. Stop the machine. Lower the work tools. Move the
obstacles. Make sure that there is adequate Hydraulic lockout control to the LOCKED position.
overhead clearance. Stop the engine.
SEBU7342-08 213
Maintenance Section
Undercarriage - Check
i00059532
Undercarriage - Check
SMCS Code: 4150-535
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Illustration 460
Window Washer Reservoir - 3. Fill the window washer reservoir with washer fluid
through the filler opening.
Fill
4. Install the filler cap.
SMCS Code: 7306-544-KE
5. Close the access door.
NOTICE
When operating in freezing temperatures, use i01258249
Caterpillar or any commercially available nonfreezing
window washer solvent. Window Wiper -
Inspect/Replace
SMCS Code: 7305-040; 7305-510
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Windows - Clean
SMCS Code: 7310-070; 7340-070
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Illustration 462
Typical example
Cleaning Methods
Aircraft Windshield Cleaner
Apply the cleaner with a soft cloth. Rub the window
with moderate pressure until all the dirt is removed.
Allow the cleaner to dry. Wipe off the cleaner with a
clean soft cloth.