Manual Maintenance Interval Schedule Caterpillar 320d R L Hydraulic Excavators

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320D RR and 320D LRR

EXCAVATORS
Maintenance Intervals
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134 SEBU8044-01
Maintenance Section
Maintenance Interval Schedule
i02517979 Fuel System - Prime ........................................... 160

Fuses - Replace .................................................. 163
Maintenance Interval Schedule High Intensity Discharge Lamp (HID) - Replace .. 165
Hydraulic System Biodegradable Oil Filter Element -
SMCS Code: 7000 Replace ............................................................. 165
Hydraulic Tank Screen - Clean ........................... 177
Ensure that all safety information, warnings, and Oil Filter - Inspect ................................................ 179
instructions are read and understood before any Radiator Core - Clean ......................................... 180
operation or any maintenance procedures are Track Adjustment - Adjust ................................... 186
performed. Window Washer Reservoir - Fill .......................... 189
Window Wiper - Inspect/Replace ........................ 189
The user is responsible for the performance of Windows - Clean ................................................. 189
maintenance, including all adjustments, the use of
proper lubricants, fluids, filters, and the replacement Every 10 Service Hours or Daily for First 100
of components due to normal wear and aging. Failure Hours
to adhere to proper maintenance intervals and
procedures may result in diminished performance of Boom and Stick Linkage - Lubricate ................... 138
the product and/or accelerated wear of components. Bucket Linkage - Lubricate ................................. 140
Use mileage, fuel consumption, service hours, or Every 10 Service Hours or Daily
calendar time, WHICH EVER OCCURS FIRST,
in order to determine the maintenance intervals. Cooling System Coolant Level - Check .............. 150
Products that operate in severe operating conditions Engine Oil Level - Check .................................... 156
may require more frequent maintenance. Fuel System Water Separator - Drain ................. 162
Fuel Tank Water and Sediment - Drain ............... 163
Note: Before each consecutive interval is performed, Hydraulic System Oil Level - Check ................... 176
all maintenance from the previous interval must be Indicators and Gauges - Test .............................. 179
performed. Seat Belt - Inspect .............................................. 181
Track Adjustment - Inspect ................................. 187
The normal oil change interval for the engine is Travel Alarm - Test .............................................. 188
Every 500 Service Hours or 3 Months. If the engine Undercarriage - Check ........................................ 188
is operated under severe conditions, change the
oil after Every 250 Service Hours or 1 Month. Every 10 Service Hours or Daily for Machines
Severe conditions include the following factors: high Used in Severe Applications
temperatures, continuous high loads, and extremely
dusty conditions . Bucket Linkage - Lubricate ................................. 140
Refer to the results of the S·O·S oil analysis in order Every 50 Service Hours or Weekly
to determine if the oil change interval should be
decreased to 250 hours. Consult your Caterpillar Bucket Linkage - Lubricate ................................. 140
dealer for detailed information regarding the optimum Quick Coupler - Lubricate ................................... 180
oil change interval.
Every 100 Service Hours or 2 Weeks for
Refer to Operation and Maintenance Manual, Machines Used in Severe Applications
Hydraulic System Oil - Change for information on
a 4000 hour maintenance interval for the hydraulic Boom and Stick Linkage - Lubricate ................... 138
system.
Initial 250 Service Hours
When Required Engine Valve Lash - Check ................................. 159
Air Conditioner/Cab Heater Filter (Recirculation) - Final Drive Oil - Change ..................................... 159
Inspect/Replace ................................................ 136 Hydraulic System Oil Filter (Case Drain) -
Battery - Recycle ................................................ 136 Replace ............................................................. 171
Battery or Battery Cable - Inspect/Replace ........ 136
Bucket Linkage - Inspect/Adjust ......................... 139 Every 250 Service Hours
Bucket Tips - Inspect/Replace ............................ 141 Engine Oil Sample - Obtain ................................ 157
Bucket Tips - Inspect/Replace ............................ 144 Final Drive Oil Sample - Obtain .......................... 160
Cab Air Filter (Fresh Air) - Clean/Replace .......... 147
Circuit Breakers - Reset ...................................... 147
Engine Air Filter Primary Element - Every 250 Service Hours or Monthly
Clean/Replace .................................................. 152 Belt - Inspect/Adjust/Replace .............................. 137
Engine Air Filter Secondary Element - Replace .. 155 Condenser (Refrigerant) - Clean ........................ 148
SEBU8044-01 135
Maintenance Section
Maintenance Interval Schedule
Final Drive Oil Level - Check .............................. 159 Every 12 000 Service Hours or 6 Years
Swing Bearing - Lubricate ................................... 182
Swing Drive Oil Level - Check ............................ 183 Cooling System Coolant (ELC) - Change ........... 148
Initial 500 Hours (for New Systems, Refilled

Systems, and Converted Systems)
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 152
Every 500 Service Hours

Obtain ............................................................... 151
Hydraulic System Oil Sample - Obtain ............... 177
Swing Drive Oil Sample - Obtain ........................ 184
Every 500 Service Hours or 3 Months

Engine Crankcase Breather - Clean ................... 155
Engine Oil and Filter - Change ........................... 157
Fuel System - Prime ........................................... 160
Fuel System Filter - Replace .............................. 161
Fuel System Primary Filter (Water Separator)
Element - Replace ............................................ 161
Fuel Tank Cap and Strainer - Clean ................... 162
Every 600 Service Hours of Continuous

Hammer Use
Hydraulic System Oil - Change ........................... 166
Every 1000 Service Hours or 6 Months

Battery - Clean .................................................... 136
Battery Hold-Down - Tighten ............................... 136
Boom and Stick Linkage - Lubricate ................... 138
Engine Valve Lash - Check ................................. 159
Final Drive Oil Level - Check .............................. 159
Hydraulic System Oil Filter (Return) - Replace ... 172
Swing Drive Oil - Change ................................... 182
Every 2000 Service Hours or 1 Year

Final Drive Oil - Change ..................................... 159
Refrigerant Dryer - Replace ................................ 181
Swing Gear - Lubricate ....................................... 184
Every Year
Obtain ............................................................... 152
Every 3 Years After Date of Installation or

Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 182
Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .. 150
136 SEBU8044-01
Maintenance Section
Air Conditioner/Cab Heater Filter (Recirculation) - Inspect/Replace
i02459073 i00993589
Air Conditioner/Cab Heater Battery - Recycle

Filter (Recirculation) - SMCS Code: 1401-561
Inspect/Replace
Always recycle a battery. Never discard a battery.
SMCS Code: 1054-040-A/C; 1054-510-A/C
Always return used batteries to one of the following
NOTICE locations:
An air recirculation filter element plugged with dust will
result in decreased performance and service life to the A battery supplier
air conditioner or cab heater.
An authorized battery collection facility
To prevent decreased performance, clean the filter el-
ement, as required. Recycling facility
i00934872
Battery Hold-Down - Tighten

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

prevent the batteries from moving during machine
operation.
i01913589
Battery or Battery Cable -

Illustration 199
g01100988 Inspect/Replace
SMCS Code: 1401-040; 1401-510; 1401-561; 1401;
The air conditioner filter is located on the lower left
1402-040; 1402-510
side of the cab behind the seat.
1. Slide the operator seat forward.
2. Slide the filter element upward. Personal injury can result from battery fumes or
explosion.
3. Tap the air filter in order to remove the dirt. Do not
use compressed air to clean the filter. Batteries give off flammable fumes that can ex-
plode. Electrolyte is an acid and can cause per-
4. After you clean the filter element, inspect the filter sonal injury if it contacts the skin or eyes.
element. If the filter element is damaged or badly
contaminated, use a new filter element. Make sure Prevent sparks near the batteries. Sparks could
that the filter element is dry. cause vapors to explode. Do not allow jumper ca-
ble ends to contact each other or the engine. Im-
5. Install the filter element. proper jumper cable connections can cause an ex-
plosion.
i00934864
Always wear protective glasses when working
Battery - Clean with batteries.
SMCS Code: 1401-070 1. Turn the engine start switch key to the OFF
position. Turn all of the switches to the OFF
Clean the battery surface with a clean cloth. Keep the position.
terminals clean and keep the terminals coated with
petroleum jelly. Install the post cover after you coat 2. Turn the battery disconnect switch to the OFF
the terminal post with petroleum jelly. position. Remove the key.
SEBU8044-01 137
Maintenance Section
Belt - Inspect/Adjust/Replace
3. Disconnect the negative battery cable at the If new belts are installed, recheck the belt adjustment
battery. after 30 minutes of operation. If two belts or more are
required for an application, replace the belts in belt
4. Disconnect the positive battery cable at the sets. If only one belt of a matched set is replaced, the
battery. new belt will carry more load. This is due to the fact
that the older belts are stretched. The additional load
5. Disconnect the battery cables at the battery on the new belt could cause the new belt to break.
disconnect switch. The battery disconnect switch
is connected to the machine frame.
Water Pump Belt, Fan Drive Belt,
6. Make necessary repairs or replace the battery. and Alternator Belt
7. Connect the battery cable at the battery disconnect
switch.
8. Connect the positive battery cable of the battery.
9. Connect the negative battery cable of the battery.
10. Install the key and turn the battery disconnect

switch to the ON position.
i02360330
Belt - Inspect/Adjust/Replace
g00686313
Illustration 201
SMCS Code: 1357-025; 1357-040; 1357-510;
1397-025; 1397-040; 1397-510 1. Open the engine hood.
g00937677
Illustration 202
2. Apply approximately 98 N (22 lb) force midway

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

Illustration 200 g00937676 deflect 10 to 12 mm (0.4 to 0.5 inch).
Your engine is equipped with a water pump, with 4. If the deflection is not correct, loosen alternator
a fan drive, and with an alternator. Your engine mounting bolt (1) and bracket bolt (2). Turn
can also be equipped with an air conditioner belt. adjusting bolt (3) in order to adjust the belt tension.
For maximum engine performance and maximum
utilization of your engine, inspect the belts for wear 5. When the adjustment is correct, tighten bolt (1)
and for cracking. Check the belt tension. Adjust the and bolt (2).
belt tension in order to minimize belt slippage. Belt
slippage will decrease the belt life. Belt slippage will 6. Check the deflection of the belt again.
also cause poor performance of the alternator and
of any driven equipment.
138 SEBU8044-01
Maintenance Section
Boom and Stick Linkage - Lubricate
7. If a new belt is installed, run the engine at i01933858

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

under water.
Wipe all fittings before you apply lubricant.
g01162234
Illustration 203
(4) Nut
(5) Adjusting Bolt
1. Apply approximately 100 N (22 lb) force midway

between the pulleys.
g00685797
2. Measure the deflection of the belt. The belt should Illustration 204
deflect 7 to 10 mm (0.3 to 0.4 inch).
1. Apply lubricant through the fitting at the base of
3. If the deflection is not correct, loosen nut (4). Turn each boom cylinder.
adjusting bolt (5) in order to adjust the belt tension.
4. When the adjustment is correct, tighten nut (4) to

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

adjustment again after 30 minutes of engine
operation at the rated engine speed.
6. Close the engine hood.
g00685798
Illustration 205
2. The fittings are at the base of the boom. The

fittings can be serviced from the platform on top
of the storage box. To lubricate the lower boom
bearings, apply lubricant through fittings (1) and
(2).
SEBU8044-01 139
Maintenance Section
Bucket Linkage - Inspect/Adjust
3. Apply lubricant through fittings (3) and (4) for the i02168785
boom cylinder rod.
Bucket Linkage -
4. Apply lubricant through fitting (5) for the stick
cylinder head.
Inspect/Adjust
SMCS Code: 6513-025; 6513-040
Note: To ensure proper lubrication of the lower
boom bearings and of the boom cylinder rod end
bearings, lubricant should be applied through fittings
(1), (2), (3), and (4). Apply lubricant first when the
boom is raised and any attachment is suspended. Unexpected machine movement can cause injury
Then apply lubricant when the boom is lowered and or death.
the attachment is rested on the ground with a slight
downward pressure. To avoid possible machine movement, move the
hydraulic lockout control to the locked position
and attach a Special Instruction, SEHS7332, Do
Not Operate or similar warning tag to the hy-
draulic lockout control.
NOTICE
Improperly adjusted bucket clearance could cause
galling on the contact surfaces of the bucket and
stick, resulting in excessive noise and/or damaged
O-ring seals.
g00685799
Illustration 206
5. Apply lubricant through fitting (6). Fitting (6) is at

the connection point of the boom and of the stick.
g00101687
Illustration 208
(1) No gap
(2) Stick boss
(3) Bucket clearance
(4) Shims
(5) Pin
(6) Plate
(7) Bolts
(8) Washers
g00685800 (9) Location
Illustration 207
(10) Flange
(11) Bucket boss
6. Apply lubricant through fitting (7) on the stick
cylinder rod, fitting (8) at the connection point of The clearance of the bucket control linkage on
the boom and of the stick, and fitting (9) at the this machine can be adjusted by shimming. If the
bucket cylinder head end. gap between the bucket and the stick becomes
excessive, adjust bucket clearance (3) to 0.5 to 1 mm
(.02 to .04 inch).
Two shims of different thickness are used at location

(9). The thicknesses of the shims are 0.5 mm
(0.02 inch ) and 1.0 mm (0.04 inch).
140 SEBU8044-01
Maintenance Section
Bucket Linkage - Lubricate
i01936491
Bucket Linkage - Lubricate

SMCS Code: 6513-086
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
molybdenum grease.

g00102146
Illustration 209
Area for linkage adjustment
1. Position the machine on a level surface and lower

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

boss (2) and the bucket boss (11) are in full face
contact at no gap (1). This will help to determine
the total clearance of the connection point of the
stick and of the bucket.
3. Place the hydraulic lockout control in the LOCKED

position and stop the engine. g00750605
Illustration 210
4. Measure bucket clearance (3), which is the
existing total clearance. Note: Completely fill all cavities of the bucket control
linkage with grease when you initially install a bucket.
5. Determine the number of shims that need to be
removed from shims (4) by using the following 1. Apply lubricant through fittings for the linkages (1),
calculation: (2), (3), and (4).
Subtract 0.5 mm (0.02 inch ) or 1.0 mm (0.04 inch) 2. Apply lubricant through fittings for the bucket (5),
from bucket clearance (3). (6), and (7). Continue to fill with grease until the
grease is visible on both sides of the power link.
6. Remove the appropriate number of shims at
location (9) in order to meet the above thickness. Note: Service the above fittings after you operate
Make sure that you use a minimum of three the bucket under water.
0.5 mm (0.02 inch) shims. To remove the shims,
remove bolts (7), washers (8), and plate (6). Installation of the Bucket
7. After the correct number of shims has been Use the procedure that follows when a bucket is
removed and pin (5) is aligned with the pin changed. Use the procedure that follows when a new
hole, install plate (6), washers (8), and bolts (7). pin is installed. Use the procedure that follows when
Tighten bolts (7) to a torque of 240 ± 40 N·m new bearings are installed.
(175 ± 30 lb ft).
Note: Fill the cavity of the stick nose with grease
8. After installation, make sure that bucket clearance before you install the pin.
(3) is still correct.
1. Insert the pin into the stick nose.
2. Secure the bucket to the stick.

SEBU8044-01 141
Maintenance Section
Bucket Tips - Inspect/Replace
g00840339 g01055179
Illustration 211 Illustration 212
(5) Fitting Acceptable wear
(8) Plug
3. Remove plug (8).
4. Apply grease through fitting (5).
5. Fill until grease flows out of plug (8).
6. Install plug (8) and tighten plug (8).
7. Continue to fill with grease until the grease is

visible on both sides of stick nose.
8. Apply lubricant through fittings for the bucket

(6), and (7). Continue to fill with grease until the
grease is visible on both sides of power link. g01055196
Illustration 213
Replace this bucket tip.
i02420541
Check the bucket tips for wear. If the bucket tip has a
Bucket Tips - Inspect/Replace hole, replace the bucket tip.
(Drive-through System)
SMCS Code: 6805-040; 6805-510
Personal injury or death can result from bucket

falling.
Block the bucket before changing bucket tips or

side cutters.
Bucket Tips g01053737

Illustration 214
Note: In order to maximize the life of the bucket tip (1) Bucket tip
and the penetration of the bucket tip, the bucket tip (2) Retainer
(3) Adapter
can be rotated.
142 SEBU8044-01
Maintenance Section
Removal Procedure 2. Remove the bucket tip from the adapter with a
slight counterclockwise rotation.
Note: Retainers are often damaged during the
removal process. Caterpillar recommends the Installation Procedure
installation of a new retainer when bucket tips are
rotated or replaced. 1. Clean the adapter, if necessary.
2. Install the new bucket tip or the rotated bucket tip

onto the adapter with a slight clockwise rotation.
g01054386
Illustration 215
Internal view
1. The retainer can be removed from the top of the g01053732

Illustration 217
bucket tip or from the bottom of the bucket tip. Use Proper location for installing the retainer
one of the following methods in order to remove
the retainer from the bucket tip:
Use a hammer and a punch in order to drive out

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

step 1.b for the procedure.
g01053731
Illustration 218
Internal View
The latch of the retainer is properly seated in the recess of the
bucket tip.
3. The retainer can be installed from the top of the

bucket tip or from the bottom of the bucket tip. Use
g01055210 one of the following methods in order to install the
Illustration 216
retainer into the bucket tip:
Pin removal tool
Use a hammer in order to drive the retainer into
Note: Carefully follow all safety instructions that are the bucket tip. A punch may be necessary in
provided with the pin removal tool. order to ensure that the latch of the retainer is
properly seated into the recess of the bucket tip.
a. Use a hammer and the short punch of the pin
removal tool in order to unseat the retainer. Use a pin removal tool. Follow step 3.a through
step 3.b for the procedure.
b. Use a hammer and the long punch of the pin
removal tool in order to completely remove the a. Use a hammer in order to drive the retainer
retainer from the bucket tip. into the bucket tip.
SEBU8044-01 143
Maintenance Section
b. Use a hammer and the short punch of the pin

removal tool in order to ensure that the latch of
the retainer is properly seated into the recess
of the bucket tip.
g01092810
Illustration 221
(A) Side cutter
Note: Some side cutters may be rotated for additional

g01054753 wear.
Illustration 219
A properly installed retainer does not extend beyond the ear of
the bucket tip. 3. Install the side cutter.
4. The retainer is properly seated if the retainer can Note: Certain bolts may require thread compound.
be moved slightly by the technicians hand. If the
retainer cannot be moved, use the punch or the 4. Hand tighten the bolts.
pin removal tool in order to adjust the retainer,
as needed. The ends of the retainer should not
extend beyond the ear of the bucket tip.
Side Cutters
g01092812
Illustration 222
Section B-B From Illustration 221
(A) Side cutter
(C) Shear ledge on a side cutter
(D) Side plate on a bucket
g01092808 (E) 0.0 mm (0.0 inch)
Illustration 220
Bucket with side cutters 5. Make sure that there is not a gap between the
(A) Side cutters side plate on the bucket and the shear ledge on
the side cutter.
1. Remove the mounting bolts and the side cutters.
6. Torque the mounting bolts to the correct
2. Clean the mounting surface of the side plate on specification.
the bucket and of the side cutter. Remove any
burrs or protrusions on the mating surfaces.
144 SEBU8044-01
Maintenance Section
i02420545

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

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

tective face shield when striking the pin.
The pin, when struck, can fly out and cause injury Illustration 224
g00590670
to nearby personnel.
(4) Back of Pin-Master
(5) Extractor
Bucket Tips a. Place the Pin-Master on the bucket tip.
b. Align extractor (5) with the pin.
c. Strike the Pin-Master at the back of the tool

(4) and remove the pin.
Note: Discard the old pin and the retainer assembly.

When you change tips, use a new pin and a new
retainer assembly. Refer to the appropriate parts
manual for your machine.
g00101352
Illustration 223
(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 225
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.
SEBU8044-01 145
Maintenance Section
g00101359 g01209140
(4) Back of Pin-Master
4. Install the new bucket tip onto the adapter. (9) Pin holder
(10) Pin setter
Note: The bucket tips can be rotated by 180 degrees
in order to allow the tip to wear evenly. You may also b. Place the Pin-Master over the bucket tips so
move the tips from the outside teeth to the inside that the pin will fit into the counterbore of the
teeth. Check the tips often. If wear is present on the pin holder (9).
tips, rotate the tips. The outside teeth generate the
most wear. c. Strike the Pin-Master with a hammer at the
back of the tool (4) in order to insert the pin.
5. Drive the pin through the bucket tip. The pin can
be installed by using one of the following methods: d. Slide pin holder (9) away from the pin and
rotate the tool slightly in order to align pin setter
From the same side of the retainer, drive the pin (10) with the pin.
through the bucket tip, the retainer assembly,
and the adapter.
Use a Pin-Master. Follow Step 5.a through Step

5.e for the procedure.
g01209159
Illustration 229
Final assembly of pin into bucket tip.
e. Strike the end of the tool until the pin is fully

inserted.
g01209166
Illustration 227
(8) Pin
a. Insert pin (8) through the bucket tip.

146 SEBU8044-01
Maintenance Section
Side Cutters
g01092812
Illustration 232
g01092808
Illustration 230 Section B-B From Illustration 231
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 231
(A) Side cutter
Note: Some side cutters may be rotated for additional

wear.
3. Install the side cutter.

g00851494
Note: Certain bolts may require thread compound. Illustration 233
4. Hand tighten the bolts.

SEBU8044-01 147
Maintenance Section
Cab Air Filter (Fresh Air) - Clean/Replace
The cab air filter is behind the cab.
1. Loosen bolt (1) and open filter cover (2).
g00851496
Illustration 234
(11) Side protector
(12) Pin
(13) Retainer g00730032
Illustration 236
(14) side plate
(2) Filter cover
(3) Air filter
1. Hit pin (12) from the retainer side of the bucket
in order to remove side protector (11) from side
plate (14). 2. Remove air filter (3) from filter cover (2).
2. Clean side protector (11), pin (12), retainer (13) 3. Clean the air filter with a maximum of 200 kPa
and side plate (14) before installation. (30 psi) pressure air.
3. Put retainer (13) in side plate (14). 4. After you clean the air filter, inspect the air filter.
If the air filter is damaged or badly contaminated,
4. Align two pin holes of the new protector and the use a new air filter.
side plate. Hit the pin from the side of the bucket
without the retainer. 5. Install the air filter and the filter cover.
Note: If the pin and/or the retainer are worn, replace Note: Make sure that the arrow on top of the air filter
the pin and/or the retainer. is facing forward.
i02221264
i01547055
Cab Air Filter (Fresh Air) - Circuit Breakers - Reset

Clean/Replace SMCS Code: 1420-529
SMCS Code: 7342-070; 7342-510 Open the access door on the left side of the machine.
g00730030 g01120975
(1) Bolt
(2) Filter cover
148 SEBU8044-01
Maintenance Section
Condenser (Refrigerant) - Clean
Main Breaker (1) This circuit breaker is designed 4. Close the access door.
to protect the electrical system. The circuit breaker
has a capacity of 80 Amp.
i01844162
Air Inlet Heater Circuit (2) This circuit breaker is

designed to protect the air inlet heater. The circuit
Cooling System Coolant (ELC)
breaker has a capacity of 120 Amp. - Change
Alternator Circuit (3) This circuit breaker is SMCS Code: 1350-044
designed to protect the alternator. If the batteries are
installed with reversed polarity, the circuit breaker NOTICE
would prevent the alternator from damaging the Do not change the coolant until you read and under-
rectifier. The circuit breaker has a capacity of 80 Amp. stand the cooling system information in Special Pub-
lication, SEBU6250, Caterpillar Machine Fluids Rec-
Circuit Breaker Reset Push in the button in order ommendations.
to reset the circuit breaker. If the electrical system is
working properly, the button will remain depressed. Failure to do so could result in damage to the cooling
If the button does not remain depressed, check the system components.
appropriate electrical circuit. Repair the electrical
circuit, if necessary.
NOTICE
Mixing ELC with other products will reduce the effec-
i01509716 tiveness of the coolant.
Condenser (Refrigerant) - This could result in damage to cooling system compo-
Clean nents.
SMCS Code: 1805-070 If Caterpillar products are not available and com-
mercial products must be used, make sure they
NOTICE have passed the Caterpillar EC-1 specification for
If excessively dirty, clean condenser with a brush. To pre-mixed or concentrate coolants and Caterpillar
prevent damage or bending of the fins, do not use a Extender.
stiff brush.
Note: This machine was filled at the factory with
Repair the fins if found defective. Caterpillar Extended Life Coolant.
1. Open the access door on the left side of the If the coolant in the machine is changed to Extended
machine. Life Coolant from another type of coolant, see Special
Publication, SEBU6250, Caterpillar Machine Fluids
Recommendations.
1. Unlatch the engine hood and raise the engine

hood.
g00537515
Illustration 238
Typical example
2. Inspect the condenser for debris. Clean the

condenser, if necessary. g00544510
Illustration 239
3. Use clean water to wash off all dust and dirt from
the condenser.
SEBU8044-01 149
Maintenance Section
Cooling System Coolant (ELC) - Change
2. Slowly loosen the pressure cap that is on the 8. Add the Extended Life Coolant. Refer to the
radiator in order to release pressure from the following topics:
cooling system.
Special Publication, SEBU6250, Caterpillar
3. Remove the pressure cap. Machine Fluids Recommendations
Operation and Maintenance Manual,

Capacities (Refill)
9. Start the engine. Operate the engine without

the cooling system pressure cap until the water
temperature regulator opens and the coolant level
stabilizes.
10. Maintain the coolant level within 13 mm (.5 inches)

of the bottom of the filler pipe.
11. Inspect the gasket of the cooling system pressure

cap. If the gasket is damaged, replace the
pressure cap.
g00544378
Illustration 240
12. Install the cooling system pressure cap.
Note: Refer to Operation and Maintenance Manual,
General Hazard Information for information that 13. Stop the engine.
pertains to containing fluid spillage.
14. Open the left access door.
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 flush the cooling
system.
a. Close the drain valve.
b. Fill the cooling system with clean water.

g00545226
c. Install the pressure cap. Illustration 241
(1) FULL
d. Start the engine and run the engine until the (2) LOW
engine reaches operating temperature.
15. Check the coolant reservoir. Maintain the coolant
e. Stop the engine and allow the engine to cool. level between FULL mark (1) and LOW mark
(2).
f. Loosen the pressure cap slowly in order to
relieve any pressure in the cooling system. 16. If additional coolant is necessary, remove the
reservoir cap and add the appropriate coolant
g. Open the drain valve that is underneath the solution.
radiator and allow the coolant to drain into a
suitable container. 17. Install the reservoir cap.
h. Flush the radiator with clean water until the 18. Close the engine hood and latch the engine hood.
draining water is transparent. Close the left access door.
7. Close the drain valve and install the access cover

underneath the radiator.
150 SEBU8044-01
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
i01952445 Note: Refer to Operation and Maintenance Manual,

General Hazard Information for information on
Cooling System Coolant containing fluid spillage.
Extender (ELC) - Add 5. It may be necessary to drain some coolant from
SMCS Code: 1352; 1353; 1395 the radiator so that Caterpillar Extender can be
added to the cooling system.
Use Caterpillar Extended Life Coolant (ELC) when
you add coolant to the cooling system. See Special Note: Always discard drained fluids according to
Publication, SEBU6250, Caterpillar Machine local regulations.
Fluids Recommendations for all cooling system
requirements. 6. AddCaterpillar Extended Life Coolant (ELC) to the
cooling system. Refer to the following topics for
Use a Coolant Conditioner Test Kit in order to check the proper amount of Caterpillar Extender:
the concentration of the coolant.
Machine Fluids Recommendations
NOTICE
Mixing ELC with other products will reduce the effec-
tiveness of the coolant. Operation and Maintenance Manual,
Capacities (Refill)
This could result in damage to cooling system compo-
7. Inspect the gasket of the cooling system pressure
nents.
cap. If the gasket is damaged, replace the
pressure cap.
If Caterpillar products are not available and com-
mercial products must be used, make sure they
8. Install the cooling system pressure cap.
have passed the Caterpillar EC-1 specification for
pre-mixed or concentrate coolants and Caterpillar
9. Close the engine hood and latch the engine hood.
Extender.
Note: This machine was filled at the factory with i02016149
Caterpillar Extended Life Coolant. Cooling System Coolant Level

1. Park the machine on level ground. - Check
2. Stop the engine. SMCS Code: 1350-040; 1350-535-FLV;
1395-535-FLV
3. Unlatch the engine hood and raise the engine
hood. 1. Open the left rear access door.
g00544510 g00545226
(1) FULL level
4. Make sure that the cooling system has cooled (2) LOW level
down. Loosen the cooling system pressure
cap slowly in order to relieve system pressure. 2. Check the coolant level of the coolant reservoir.
Remove the pressure cap. 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.
SEBU8044-01 151
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
a. Unlatch the engine hood and raise the engine 4. Install the reservoir cap.
hood.
5. Close the left access door.
i02250847
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 filled
with Cat ELC (Extended Life Coolant). Cooling
systems that are filled with Cat ELC should have
a Coolant Sample (Level 2) that is obtained at
g00544510
Illustration 244 the recommended interval that is stated in the
Maintenance Interval Schedule.
b. Slowly loosen the cooling system pressure cap
in order to relieve system pressure. Remove Note: Obtain a Coolant Sample (Level 1) if the
the pressure cap. cooling system is filled with any other coolant
instead of Cat ELC. This includes the following
Note: Refer to Operation and Maintenance Manual, types of coolants.
containing fluid spillage. Commercial long life coolants that meet the
Caterpillar Engine Coolant Specification -1
c. Add the appropriate coolant solution to the (Caterpillar EC-1)
cooling system. Refer to the following topics:
Cat Diesel Engine Antifreeze/Coolant (DEAC)
Machine Fluids Recommendations Commercial heavy-duty coolant/antifreeze
Operation and Maintenance Manual, NOTICE
Capacities (Refill)
Always use a designated pump for oil sampling, and
d. Start the engine. Operate the engine without use a separate designated pump for coolant sampling.
the cooling system pressure cap until the water Using the same pump for both types of samples may
temperature regulator opens and the coolant contaminate the samples that are being drawn. This
level stabilizes. contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
e. Maintain the coolant level within 13 mm dealers and customers.
(0.5 inch) of the bottom of the filler pipe.
Note: Level 1 results may indicate a need for
f. Inspect the condition of the gasket on the Level 2 Analysis.
pressure cap. If the gasket is damaged, replace
the pressure cap. NOTICE
Care must be taken to ensure that fluids are contained
g. Install the cooling system pressure cap. during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
h. Stop the engine. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
i. Close the engine hood and latch the engine nent containing fluids.
hood.
Refer to Special Publication, NENG2500, Caterpillar
Note: Refer to Operation and Maintenance Manual, Tools and Shop Products Guide for tools and supplies
General Hazard Information for information on suitable to collect and contain fluids on Caterpillar
containing fluid spillage. products.
3. If additional coolant is necessary, remove the Dispose of all fluids according to local regulations and
reservoir cap and add the appropriate coolant mandates.
solution.
152 SEBU8044-01
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
i02049802
Cooling System Coolant

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

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

to the recommended sampling interval. Supplies
Illustration 245
g00811362 for collecting samples can be obtained from your
Caterpillar dealer.
A typical example is shown.
Submit the sample for Level 2 analysis.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order Reference: For additional information about coolant
to receive the full effect of S·O·S analysis, you analysis, refer to Special Publication, SEBU6250,
must establish a consistent trend of data. In order Caterpillar Machine Fluids Recommendations or
to establish a pertinent history of data, perform consult your Caterpillar dealer.
consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer. i02034899
Use the following guidelines for proper sampling of Engine Air Filter Primary
the coolant: Element - Clean/Replace
Complete the information on the label for the SMCS Code: 1054-070; 1054-510
sampling bottle before you begin to take the
samples. If a warning and a pictograph is displayed on the
message display or if the exhaust is black, check the
Keep the unused sampling bottles stored in plastic primary filter.
bags.
1. Open the access door on the left side of the
Obtain coolant samples directly from the coolant machine.
sample port. You should not obtain the samples
from any other location.
Keep the lids on empty sampling bottles until you

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

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

Never collect samples from the drain for a system.
Submit the sample for Level 1 analysis.
g00537958
Illustration 246
For additional information about coolant analysis, see
Special Publication, SEBU6250, Caterpillar Machine 2. Squeeze the outlet tube slightly in order to purge
Fluids Recommendations or consult your Caterpillar the dirt from the outlet tube.
dealer.
SEBU8044-01 153
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
g00101413 g00101416
3. Loosen the cover latches and remove the air Note: Install the air cleaner cover properly. The
cleaner cover. arrows must point upward.
9. Change the filter if any of the following conditions

occurs:
Restricted Air Filter indicator on the monitor

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

of a primary filter.
10. Close the access doors.
Cleaning Primary Air Filter

g00101415
Elements
Illustration 248
NOTICE
4. Remove the primary filter element from the air Caterpillar recommends certified air filter cleaning ser-
cleaner housing. vices available at participating Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
5. Clean the air cleaner cover and the inside of the to assure consistent quality and sufficient filter life.
air cleaner housing.
Observe the following guidelines if you attempt to
6. Inspect the O-ring seal on the air cleaner cover. clean the filter element:
Replace the O-ring seal if the O-ring seal is worn
or damaged. Do not tap or strike the filter element in order to re-
move dust.
7. Install the clean primary filter.
Do not wash the filter element.
Note: Refer to Cleaning Primary Air Filter Elements.
Use low pressure compressed air in order to remove
8. Install the air cleaner cover and close the latches the dust from the filter element. Air pressure must not
securely. exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets, or

seals. Dirt entering the engine will cause damage to
engine components.
154 SEBU8044-01
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
When the primary air filter element is cleaned, check Aim the hose so that the air flows inside the element
for rips or tears in the filter material. Replace the along the length of the filter in order to help prevent
primary air filter element after the primary air filter damage to the paper pleats. Do not aim the stream of
element has been cleaned six times. The primary air air directly at the primary air filter element. Dirt could
filter element should be replaced at least one time be forced further into the pleats.
per year. This replacement should be performed
regardless of the number of cleanings. Vacuum Cleaning
NOTICE Vacuum cleaning is another method for cleaning
Do not clean the air filter elements by bumping or tap- primary air filter elements which require daily cleaning
ping. This could damage the seals. Do not use ele- because of a dry, dusty environment. Cleaning with
ments with damaged pleats, gaskets, or seals. Dam- pressurized air is recommended prior to vacuum
aged elements will allow dirt to pass through. Engine cleaning. Vacuum cleaning will not remove deposits
damage could result. of carbon and oil.
Visually inspect the primary air filter elements before Inspecting the Primary Air Filter
cleaning. Inspect the air filter elements for damage Elements
to the seal, the gaskets, and the outer cover. Discard
any damaged air filter elements.
There are two common methods that are used to

clean primary air filter elements:
Pressurized air
Vacuum cleaning
Pressurized Air
Pressurized air can be used to clean primary air filter
elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of g00281693
carbon and oil. Use filtered, dry air with a maximum Illustration 251
pressure of 207 kPa (30 psi).
Inspect the clean, dry primary air filter element. Use
a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air filter
element. Rotate the primary air filter element. Inspect
the primary air filter element for tears and/or holes.
Inspect the primary air filter element for light that may
show through the filter material. If it is necessary in
order to confirm the result, compare the primary air
filter element to a new primary air filter element that
has the same part number.
Do not use a primary air filter element that has any

tears and/or holes in the filter material. Do not use
a primary air filter element with damaged pleats,
gaskets or seals. Discard damaged primary air filter
Illustration 250 g00281692 elements.
Note: When the primary air filter elements are Storing Primary Air Filter Elements
cleaned, always begin with the clean side (inside)
in order to force dirt particles toward the dirty side If a primary air filter element that passes inspection
(outside). will not be used, the primary air filter element can
be stored for future use.
SEBU8044-01 155
Maintenance Section
Engine Air Filter Secondary Element - Replace
2. See Operation and Maintenance Manual, Engine

Air Filter Primary Element - Clean/Replace.
Remove the air cleaner cover from the air cleaner
housing. Remove the primary filter element from
the air cleaner housing.
g00281694
Illustration 252
Do not use paint, a waterproof cover, or plastic as a

protective covering for storage. An airflow restriction
may result. To protect against dirt and damage, wrap
the primary air filter elements in Volatile Corrosion Illustration 253
g00101451
Inhibited (VCI) paper.
3. Remove the secondary filter element.
Place the primary air filter element into a box for
storage. For identification, mark the outside of the 4. Cover the air inlet opening. Clean the inside of
box and mark the primary air filter element. Include the air cleaner housing.
the following information:
5. Remove the cover from the air inlet opening.
Date of cleaning
6. Install the new secondary filter element.
Number of cleanings
7. Install the primary filter element.
Store the box in a dry location.
8. Install the air cleaner cover and close the latches
i01430699
securely.
Engine Air Filter Secondary 9. Close the access door.

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

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

machine.
156 SEBU8044-01
Maintenance Section
Engine Oil Level - Check
g00824179 g00937619
2. Loosen hose clamp (2) and disconnect outlet hose 2. Remove the dipstick. Wipe the oil off the dipstick
(1) from breather (3). and insert the dipstick.
3. Remove breather (3) and O-ring seal (4).
4. Wash breather (3) in clean, nonflammable solvent.
5. Inspect O-ring seal (4). If the seal is damaged,

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

clamp (2).
8. Close the engine hood.

g00824185
Illustration 256
i02224984
Engine Oil Level - Check 3. Remove the dipstick and check the dipstick. The
oil level should be between the H mark and the
L mark.
SMCS Code: 1000-535
NOTICE
NOTICE
Operating your engine when the oil level is above the
Do not overfill the crankcase. Engine damage can re-
H mark could cause the crankshaft to dip into the oil.
sult.
This could lead to excessively high oil temperatures
which can reduce the lubricating characteristics of the
Note: This machine is equipped with both an oil, lead to bearing damage, and could result in loss of
automated function for checking fluid levels and engine power.
a dipstick. Refer to Operation and Maintenance
Manual, Monitoring System regarding the
automated system. If the machine is on an incline or
the engine has been stopped only for a short time,
then the engine oil does not return to the crankcase
and the fluid level cannot be properly checked by
either method. Park the machine on level ground and
check the oil level after the engine has been stopped
for at least 30 minutes.
Check the oil level while the engine is stopped. Do

not check the oil level while the engine is running.
1. Open the hood.

SEBU8044-01 157
Maintenance Section
Engine Oil Sample - Obtain
Obtain a sample of the engine oil from the engine oil

sampling valve that is located on the engine oil filter
housing. Refer to Special Publication, SEBU6250,
S·O·S Oil Analysis for information that pertains to
obtaining a sample of the engine oil. Refer to Special
Publication, PEHP6001, How To Take A Good Oil
Sample for more information about obtaining a
sample of the engine oil.
i02224999
Engine Oil and Filter - Change

SMCS Code: 1318-510
g00937631
Illustration 257
Note: If the sulfur content in the fuel is greater than
Note: Refer to Operation and Maintenance Manual, 1.5% by weight, use an oil that has a TBN of 30 and
General Hazard Information for information on reduce the oil change interval by one-half.
Containing Fluid Spillage.
Park the machine on a level surface and engage the
4. Remove the oil filler plug in order to add oil, if parking brake. Stop the engine.
necessary. See Operation and Maintenance
Manual, Capacities (Refill). Note: Drain the crankcase while the oil is warm. This
allows waste particles that are suspended in the oil to
Note: If the oil is deteriorated or badly contaminated, drain. As the oil cools, the waste particles will settle
change the oil regardless of the maintenance interval. to the bottom of the crankcase. The particles will not
be removed by draining the oil and the particles will
5. Clean the oil filler plug. Install the oil filler plug. recirculate in the engine lubrication system with the
new oil.
6. Close the hood.
i01961926
Engine Oil Sample - Obtain

SMCS Code: 1000-008; 1000; 1348-008;
1348-554-SM; 7542-008; 7542-554-OC, SM
g00101627
Illustration 259
1. The drain valve for the engine crankcase oil is

located under the rear of the upper structure.

g00684916
Illustration 258
158 SEBU8044-01
Maintenance Section
Engine Oil and Filter - Change
10. Install the new oil filter by hand.
Instructions for the installation of the filter are

printed on the side of each Caterpillar spin-on
filter. For non-Caterpillar filters, refer to the
installation instructions that are provided by the
supplier of the filter.
g00937651
Illustration 260
2. Open the crankcase drain valve. Allow the oil to

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

regulations.
g00937661
Illustration 262
3. Close the drain valve. (3) Dipstick
(4) Oil filler plug
11. Remove oil filler plug (4). Fill the crankcase
with new oil. See Operation and Maintenance
Manual, Capacities (Refill) and Operation and
Maintenance Manual, Lubricant Viscosities.
Clean the oil filler plug and install the oil filler plug.
NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
12. Start the engine and allow the oil to warm. Check
the engine for leaks. Stop the engine.
g00686495
Illustration 261
(1) Drain valve
(2) Engine oil filter
5. Open drain valve (1). The drain valve is located

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

40 ± 5 N·m (30 ± 4 lb ft).
7. Remove oil filter (2). See Operation and

Maintenance Manual, Oil Filter - Inspect. Discard Illustration 263 g00104116
the used oil filter properly.
13. Wait for 30 minutes in order to allow the oil to
8. Clean the filter housing base. Make sure that all of drain back into the crankcase. Check the oil level
the former filter gasket is removed. with dipstick (3). Maintain the oil between the H
and L marks on the dipstick. If necessary, add oil.
9. Apply a thin coat of engine oil to the gasket of the
new filter. 14. Close the engine hood.
SEBU8044-01 159
Maintenance Section
Engine Valve Lash - Check
i01747875 8. Completely remove the oil that has spilled onto

surfaces.
Engine Valve Lash - Check
9. Start the engine and allow the final drives to run
SMCS Code: 1102-082; 1102-535; 1102; 1105-025; through several cycles.
1105-535; 1121-535; 1209-082; 1209-535; 1209;
7527 10. Stop the engine. Check the oil level.
Refer to Engine Systems Operation/Testing and 11. Check the drained oil for metal chips or for
Adjusting in order to perform the complete procedure particles. If there are any chips or particles,
for the valve lash adjustment. consult your Caterpillar dealer.
i01584908
12. Properly dispose of the drained material. Obey
local regulations for the disposal of the material.
Final Drive Oil - Change
i02412068
SMCS Code: 4050-044-FLV
Final Drive Oil Level - Check
g00822278
Illustration 264
1. Position one final drive so that oil drain plug (2) is

at the bottom. Illustration 265 g00822278
Note: Refer to Operation and Maintenance Manual, 1. Position one final drive so that oil drain plug (2) is
General Hazard Information for information on at the bottom.
2. Remove drain plug (2) and level plug (1). Allow General Hazard Information for information on
the oil to drain into a suitable container. Containing Fluid Spillage.
3. Clean the plugs and inspect the O-ring seals. If 2. Remove oil level plug (1).
wear or damage is evident, replace the drain plug,
the level plug, and/or the O-ring seals. 3. Check the oil level. The oil should be near the
bottom of the level plug opening.
4. Install drain plug (2).
4. Add oil through the level plug opening, if
5. Fill the final drive to the bottom of the opening on necessary. See Operation and Maintenance,
level plug (1). See Operation and Maintenance Lubricant Viscosities.
Manual, Lubricant Viscosities and Operation and
Maintenance Manual, Capacities (Refill) . Note: Overfilling the final drive will cause the seals on
the travel motor to allow hydraulic oil or water to enter
6. Install level plug (1). the final drive. This may contaminate the final drive.
7. Perform Step 1 to Step 6 on the other final drive. 5. Clean oil level plug (1). Inspect the O-ring seal.
Use a different container for the oil so that the oil Replace the O-ring seal if the O-ring seal is worn
samples from the final drives will be separate. or damaged.
160 SEBU8044-01
Maintenance Section
Final Drive Oil Sample - Obtain
6. Install oil level plug (1).
7. Repeat the procedure for the other final drive.
i02252224
Final Drive Oil Sample - Obtain

SMCS Code: 4011-008; 4050-008; 4050-SM;
7542-008
g00686839
Illustration 267
(1) Air vent
(2) Priming pump plunger
(3) Air vent

containing fluid spillage.
2. Loosen air vent (1) on the fuel filter.

g00822278
Illustration 266
3. Rotate priming pump plunger (2) in a
(1) Oil level plug counterclockwise rotation. Rotate the plunger
(2) Oil drain plug
until the plunger becomes unlocked. Operate the
priming pump plunger.
1. Position the final drive so that oil drain plug (2) is
at the bottom. 4. Tighten air vent (1) when the fuel flow is free of
air bubbles.
2. Remove oil level plug (1).
5. Loosen air vent (3) on the fuel injector pump.
3. Obtain a sample of the final drive oil through the
hole for the oil level plug. 6. Operate priming pump plunger (2). Allow the fuel
to flow until the fuel is free of air bubbles.
4. Install oil level plug (1).
7. Push the plunger inward and rotate the plunger
Refer to Special Publication, SEBU6250, Caterpillar clockwise. This motion will lock the plunger in
Machine Fluids Recommendations, S·O·S Oil place.
Analysis for more information on obtaining a sample
of the final drive oil. For additional information about 8. Tighten vent plug (3) on the fuel injection pump.
taking an oil sample, refer to Special Publication,
PEHP6001, How To Take A Good Oil Sample. Note: Lock the priming pump plunger before vent
plug (3) is tightened. Pressure in the fuel system
i02061905 could make locking the plunger in place difficult.
Fuel System - Prime

SMCS Code: 1250-548

SEBU8044-01 161
Maintenance Section
Fuel System Filter - Replace
i02418811 6. Prime the fuel system. See Operation and

Maintenance Manual, Fuel System - Prime for
Fuel System Filter - Replace instructions.
SMCS Code: 1261-510 7. Close the engine hood.
NOTICE
Turn the disconnect switch OFF or disconnect the bat- i02418911
tery when changing fuel filters. Fuel System Primary Filter

Do not fill fuel filters with fuel before installing them. (Water Separator) Element -
Contaminated fuel will cause accelerated wear to fuel
systems parts.
Replace
SMCS Code: 1263-510-FQ

General Hazard Information for information on Personal injury or death may result from failure to
containing fluid spillage. adhere to the following procedures.
Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire.
Clean up all leaked or spilled fuel. Do not smoke

while working on the fuel system.
Turn the disconnect switch OFF or disconnect the

battery when changing fuel filters.
NOTICE
Do not fill the fuel filters with fuel before installing the
fuel filters. The fuel will not be filtered and could be
g00686799
contaminated. Contaminated fuel will cause acceler-
Illustration 268 ated wear to fuel system parts.
2. Remove the filter.
1. Open the rear access door on the left side of the
Note: Always discard used filters according to local machine.
regulations.
3. Clean the filter mounting base. Make sure that all

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

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

printed on the side of each Caterpillar spin-on filter.
For non-Caterpillar filters, refer to the installation
instructions that are provided by the supplier of the g00687097
Illustration 269
filter.
(1) Collar
(2) Water separator element
Note: You may need to use a Caterpillar strap (3) Collar
wrench, or another suitable tool, in order to turn (4) Drain valve
the filter to the amount that is required for final (5) Bowl
installation. Make sure that the installation tool does
not damage the filter.
162 SEBU8044-01
Maintenance Section
Fuel System Water Separator - Drain
2. Turn drain valve (4) counterclockwise in order to

open the drain valve. The drain valve is on the
bottom of the water separator.

General Hazard Information for information that
3. Drain the water and the sediment into a suitable

container.
Note: Dispose of used fluids according to local

regulations.
4. Close drain valve (4). g00686991

Illustration 270
5. Hold the bottom of water separator element (2)
while you loosen collar (3). 2. Turn the drain valve counterclockwise in order to
open the drain valve.
6. Remove bowl (5).
7. Loosen collar (1). General Hazard Information for information on
8. Remove water separator element (2). Discard
water separator element (2). 3. Drain the water and drain the sediment into a
suitable container.
Note: The water separator element is a cartridge
type filter. The filter cannot be reused. Note: Dispose of drained fluids according to local
regulations.
9. Clean the inside surfaces of the filter head and
of the bowl (5). 4. Close the drain valve.
10. Inspect the O-ring on bowl (5). Also inspect the 5. Close the access door.
seal on the filter head. Replace these seals if the
seals are worn or damaged. i01589598
11. Install a new water separator element. Tighten Fuel Tank Cap and Strainer -
collar (1) in order to secure the water separator
element. Clean
12. Install bowl (5). Tighten collar (3). SMCS Code: 1273-070-STR
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.
i01430725
Fuel System Water Separator

- Drain
SMCS Code: 1263 Illustration 271 g00824193
1. Open the front access door on the left side of the 1. Remove the fuel cap.
machine.
2. Inspect seal (4) for damage. Replace the seal, if
necessary.
SEBU8044-01 163
Maintenance Section
Fuel Tank Water and Sediment - Drain
3. Remove screws (1), filter assembly (2), drain Note: Refer to Operation and Maintenance Manual,
valve (3) and the gaskets. General Hazard Information for information on
1. 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 fluids according to local

regulations.
2. Close the drain valve by turning the valve

clockwise.
i02438650
Illustration 272 g00824196 Fuses - Replace

SMCS Code: 1417-510
4. Remove the strainer that is located in the filler

opening.
5. Wash the strainer and the fuel tank cap in a clean,

nonflammable solvent.
6. Install a new cap filter kit. Install the gaskets, drain

valve (3), filter assembly (2), and screws (1).
7. Install the strainer into the filler opening.
8. Install the fuel tank cap. Illustration 274 g01101038
The fuse panel is located on the right side of the

i02115478
interior storage box. Remove the cover in order to
Fuel Tank Water and Sediment access the fuses.
- Drain Fuses Fuses protect the electrical
system from damage that is caused by
SMCS Code: 1273-543 overloaded circuits. Change a fuse if the
element separates. If the element of a new fuse
The fuel tank drain valve is located underneath the separates, check the circuit and/or repair the circuit.
main hydraulic pump.
NOTICE
Always replace fuses with the same type and capacity
fuse that was removed. Otherwise, electrical damage
could result.
NOTICE
If it is necessary to replace fuses frequently, an elec-
trical problem may exist.
Contact your Caterpillar dealer.
g01043694
Illustration 273
164 SEBU8044-01
Maintenance Section
Fuses - Replace
To replace a fuse, use the puller that is stored in the (9) Lower Window Wiper and Window Washer
fuse panel. Two fuses of 5 Amperes, three fuses of 10 Amp
10 Amperes, two fuses of 15 Amperes, and one fuse
of 30 Amperes are contained in the fuse panel as (10) Window Wiper and Window Washer 10 Amp
spare fuses.
(11) Air Suspension Seat 10 Amp
The following list identifies the circuits that are
protected by each fuse. The amperage for each fuse (12) 12 Volt 7 Amp Converter 10 Amp
is included with each circuit.
(13) Beacon 10 Amp
(14) Inspection Lamp 2 10 Amp
(15) Boom Float 5 Amp
(16) Alternator Regulator 5 Amp
(17) Spare 5 Amp
(18) Spare 10 Amp
(19) Spare 10 Amp
(20) Spare 15 Amp
(21) Heater and Air Conditioner Blower Fan 15

Amp
(22) Product Link 5 Amp
(23) Boom Light 10 Amp
(24) Timer Relay 10 Amp
(25) Cab Light 10 Amp
(26) Cab Dome Light and Radio Memory 10 Amp
(27) Engine Start Switch 10 Amp
(28) Horn 10 Amp
(29) Machine Control Module 25 Amp

g01218565
Illustration 275
(30) Engine Control Module (ECM) 10 Amp
(1) Air Conditioner 15 Amp
(31) Inspection Lamp 2 10 Amp
(2) Automatic Engine Speed Control (AEC) 5
Amp (32) Electric Refueling Pump (If Equipped) 30
Amp
(3) Chassis Light 10 Amp
(33) Spare 5 Amp
(4) Cigar Lighter 10 Amp
(34) Spare 5 Amp
(5) 12 Volt 7 Amp Converter 10 Amp
(35) Spare 10 Amp
(6) Switch Panel And Radio 5 Amp
(36) Spare 10 Amp
(7) Attachment Solenoid 10 Amp
(37) Spare 15 Amp
(8) Seat Heater 5 Amp
SEBU8044-01 165
Maintenance Section
High Intensity Discharge Lamp (HID) - Replace
(38) Spare 25 Amp Note: In order to avoid failure to the bulb that is
premature, avoid touching the bulbs surface with
(39) Spare 25 Amp your bare hands. Clean any fingerprints from the bulb
with alcohol prior to operation.
(40) Spare 30 Amp
5. Reassemble the housing for the HID lamp. Ensure
that any printing on the lens is oriented correctly
i02245859
with respect to the HID lamps mounting position
High Intensity Discharge Lamp on the machine.
(HID) - Replace 6. Reattach the electrical power to the HID lamp.

(If Equipped) 7. Check the HID lamp for proper operation.
SMCS Code: 1434-510
Note: Consult your Caterpillar dealer for additional
information on HID lamps.
HID lamps operate at very high voltages. To avoid i02438701

electrical shock and personal injury, disconnect
power before servicing HID lamps.
Hydraulic System
Biodegradable Oil Filter
Element - Replace
(If Equipped)
HID bulbs become very hot during operation.
Before servicing, remove power from lamp for at SMCS Code: 5068-510
least five 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 com-
ponent, 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 five minutes, in order to ensure that the bulb
is cool. g01218672
Illustration 276
2. Disassemble the housing for the HID lamp in order

to have access to the bulb. 1. Place the machine in the servicing position.
2. Move the hydraulic lockout control to the LOCKED

Note: On some HID lamps, the bulb is an integral
position. Stop the engine.
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.
166 SEBU8044-01
Maintenance Section
Hydraulic System Oil - Change
i02439133

SMCS Code: 5056-044
4000 Hour Oil Change Interval

A 4000 hour maintenance interval for hydraulic
oil (change) is available. The extended interval
requires S·O·S monitoring of the hydraulic oil. The
interval for S·O·S monitoring is every 500 hours. The
maintenance interval for the hydraulic oil filter is not
changed. If S·O·S monitoring is not performed, the
g01218607 2000 hour maintenance interval must be used.
Illustration 277
Machines with hammers are not included in the

3. Slowly loosen the filler plug in order to relieve any
4000 hour maintenance interval. Machines with
pressure.
hammers must use the intervals that are listed in
the Maintenance Interval Schedule. Machines that
4. Tighten the filler plug after the pressure is relieved.
are used in severe conditions are not included in the
4000 hour maintenance interval. Machines that are
5. Open the access door on the right side of the
used in severe conditions must use the interval in the
machine.
Maintenance Interval Schedule.
Lubricants
Approved hydraulic oil must be used to obtain the
4000 hour hydraulic oil change. Refer to the list that
follows for approved oils.
Caterpillar Hydraulic Oils
Cat HYDO
Cat DEO
g01090728
Cat DEO SYN
Illustration 278
Cat Arctic DEO SYN
6. Remove four bolts (1) and cover (2) from the BIO
filter. Cat TDTO
7. Remove BIO filter element (3) from the filter Cat Arctic TDTO SYN
assembly.
Cat TDTO-TMS
8. Install a new filter element.
Cat MTO
9. Close the access door.
Cat BIO HYDO (HEES)
Commercial Oils
Acceptable commercial oils are identified by the

American Petroleum Institute trademark (API).
Refer to the list that follows for acceptable types of
hydraulic oils.
Engine oils that meet the Caterpillar ECF-1

specification that has a minimum zinc additive of
0.09 percent (900 ppm)
SEBU8044-01 167
Maintenance Section
API CG-4 engine oils that have a minimum zinc 2. Remove bolts (1), washers (2) and cover (3) from
additive of 0.09 percent (900 ppm) the top of the hydraulic tank.
API CF engine oils that have a minimum zinc

additive of 0.09 percent (900 ppm)
TO-4 specification oils that have a minimum zinc

additive of 0.09 percent (900 ppm)
If Cat BIO HYDO (HEES) is not used, commercial

oils that meet the Caterpillar BF-1 specifications
should be used.
Note: Industrial hydraulic oils are not recommended

for the hydraulic systems of Caterpillar machines.
Industrial hydraulic oils are more likely to allow
corrosion and Industrial hydraulic oils are more likely
g01218798
to allow excessive wear. Illustration 281
(4) Fill/Vent Plug
Lubricant Viscosities for more information on 3. Clean the area thoroughly in order to keep dirt out
hydraulic oils. of the screen cover. Clean the area thoroughly in
order to keep dirt out of the fill/vent plug (4).
Procedure to Change the Hydraulic 4. Relieve the internal pressure from the hydraulic
Oil tank by loosening the fill/vent plug. After the
pressure is relieved, remove the fill/vent plug (4).
g01218672
Illustration 279
g01218801
Illustration 282
1. Park the machine on level ground. Lower the
The hydraulic oil drain valve is located under the hydraulic tank.
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.
g01218797
Illustration 280
168 SEBU8044-01
Maintenance Section
12. Clean plug (5) and install the plug. Tighten the
plug to a torque of 75 ± 5 N·m (55 ± 48 lb ft).

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

hydraulic tank.
g01218803
Illustration 283
(5) Plug

6. Remove plug (5).

g00687275
Illustration 285
15. Remove the plug from the tube. Allow the oil to
drain into a container.
Note: Dispose of used filters and used fluids

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

damage is evident.
17. Clean the plug. Install the plug and the O-ring into
the drain port.
g01218856
Illustration 284
(6) Pipe Nipple
(7) Hose
(8) Drain Plug
7. Replace plug (5) with a 3B-7271 Pipe Nipple (6)

and hose (7).
8. Loosen drain plug (8) in order to drain the oil.
9. Drain the oil into a suitable container.
10. After the oil has been drained, tighten drain plug
(8) to a torque of 110 ± 15 N·m (81 ± 11 lb ft).
11. Remove Pipe Nipple (6) and hose (7).

SEBU8044-01 169
Maintenance Section
g01218968
Illustration 287
(14) O-ring seal
(15) O-ring seal
21. Remove O-ring seal (14) from the screen.
Illustration 286 g01218966 22. Inspect O-ring seals (14) and (15). Replace the
O-ring seals if wear or damage is evident.
(9) Bolts
(10) Washers
(11) Cover 23. Install O-ring seal (14) on screen (13).
(12) Spring
(13) Screen 24. Install screen (13) and spring (12). Then install
cover (11), washers (10), and bolts (9).
18. Remove bolts (9), washers (10) and cover (11).
Note: Make sure that the O-ring seals and the spring
Note: Dispose of used filters and used fluids are properly positioned during installation.
25. Fill the hydraulic system oil tank. Refer to
Note: Do not allow spring (12) to fall back into the Operation and Maintenance Manual, Capacities
tank. (Refill).
19. Remove spring (12) and screen (13).
Note: Refer to Operation and Maintenance, General

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

Allow the screen to dry. Inspect the screen.
Replace the screen, if the screen is damaged.
g01218798
Illustration 288
26. Inspect the O-ring seal on the filler plug for

damage. Replace the O-ring, if necessary. Clean
the filler plug. Install the filler plug.
170 SEBU8044-01
Maintenance Section
g01218975 g01218983
(16) Drain hose (20) Fitting
(17) Connector
(18) Seal h. Slowly loosen fitting (20) until the hydraulic oil
(19) Negative flow control hose
flows out of the opening. This indicates that the
Note: Make no attempt to start the engine until the air has been released from the pump.
pump has been filled with hydraulic oil. Serious
damage to the hydraulic components can result. i. Tighten fitting (20).
27. When the hydraulic oil has been replaced, the air 28. Start the engine. Operate the engine at idling
speed for five minutes.
must be removed from the hydraulic oil system.
To remove the air from the hydraulic oil system,
follow Step 27.a through Step 27.g.
a. While the engine is stopped, remove drain

hose (16), connector (17) and seal (18) from
the top of the pump. Add hydraulic oil through
the opening.
b. Check the condition of seal (18). If the seal is

damaged, replace the seal.
c. After the pump has been filled with oil, install

drain hose (16), connector (17) and seal (18) to
the original locations.
g01218672
Illustration 291
d. Start the engine. When the engine is at low
idle, fully raise the boom. Hold the boom in
29. Operate the joysticks in order to circulate the
this position. hydraulic oil. Lower the bucket to the ground so
that the stick is vertical to the ground. Stop the
e. Slowly loosen negative flow control hose (19) engine.
until the air has been released from the pump.
f. Tighten negative flow control hose (19).
g. Stop the engine. Slowly lower the boom until

the bucket is on the ground. This pressurizes
the hydraulic tank.
SEBU8044-01 171
Maintenance Section
Hydraulic System Oil Filter (Case Drain) - Replace
5. Turn the engine start switch to the OFF position

and return the lever for the hydraulic lockout
control to the LOCKED position.
g01218776
Illustration 292
(A) High Temperature Range
(B) Low Temperature Range
g01218607
Illustration 294
30. Maintain the oil level between the marks on the
sight gauge in the appropriate temperature range. 6. Slowly loosen the fill/vent plug on top of the
hydraulic tank in order to relieve the internal
31. Close the engine hood and latch the engine hood. pressure of the hydraulic tank.
i02438859
7. After the pressure is relieved, tighten the fill/vent
plug.
Hydraulic System Oil Filter
(Case Drain) - Replace
SMCS Code: 5068-510; 5091-510
g01218683
Illustration 295

machine.
g01218679
Illustration 293

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.
g01218714
Illustration 296
The case drain filter is located near the pilot oil filter.
172 SEBU8044-01
Maintenance Section
Hydraulic System Oil Filter (Return) - Replace
9. Clean the area in order to keep dirt out of the filter 17. Check the hydraulic oil level.
base.
Reference: For the correct procedure, refer to
10. Remove the used case drain filter from the filter Operation and Maintenance Manual, Hydraulic
base. System Oil Level - Check.
Note: Used filters should always be disposed of 18. Close the access door.
i02439833
11. Clean the filter base.
Hydraulic System Oil Filter
(Return) - Replace
SMCS Code: 5068-510-RJ
The return filter is a cartridge type filter. The amount

of foreign material that enters the hydraulic system is
reduced when the filter element is replaced.
Two different filters are available for the return filter.

One filter is used for standard applications such as
digging and normal use of a hammer. The second
filter is used for an application such as demolishing a
ceiling in a tunnel with a hammer.
g00101502
Illustration 297
Note: If the message display shows that the hydraulic
12. Coat the seal of a new case drain filter with clean return filter is plugged, turn off the machine. After you
hydraulic oil. make sure that the warning has disappeared, start
the machine and run the machine on level ground for
13. Install the new oil filter by hand. approximately 10 minutes. If the warning still appears
in the message display, inspect the filter and replace
Instructions for the installation of the filter are the filter, if necessary.
printed on the side of each Caterpillar spin-on
filter. For non-Caterpillar filters, refer to the
installation instructions that are provided by the
supplier of the filter.
14. Start the engine and operate the machine slowly

for 10 to 15 minutes. Move each cylinder evenly
through several cycles.
g01219019
Illustration 299
1. Remove the bolts, washers, and the cover from

the top of the hydraulic tank.
g01218672
Illustration 298
15. Return the machine to the position that is shown

in Illustration 298. Check the machine for oil leaks.
16. Stop the engine.

SEBU8044-01 173
Maintenance Section
g01219024 g00102212
(5) Filter cartridge
2. Loosen the fill/vent plug in order to relieve the (6) Filter case
hydraulic tank pressure. Tighten the fill/vent plug (A) Guide
after the hydraulic tank pressure is relieved.
c. Pull up the handle at the top of filter cartridge
Note: The return filter cartridge is located next to the (5) until the filter cartridge contacts guide (A)
fill/vent plug. on filter case (6).
3. Remove the filter cartridge. Perform Step 3.a

through Step 3.f in order to remove the filter
cartridge.
g00102214
Illustration 303
d. Turn the filter cartridge counterclockwise by

180 degrees in order to align the projection of
Illustration 301
g00102211 the filter cartridge with the notch of the filter
(1) Bolts case. Pull out the filter cartridge.
(2) Washers
(3) Cover
(4) Plug
(5) Filter cartridge
a. Remove bolts (1), washers (2), and cover (3).

b. Remove plug (4) in order to release the

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

return filter drops to the level of the hydraulic tank. Illustration 304 g00102219
(7) O-ring
174 SEBU8044-01
Maintenance Section
e. Inspect the cover and O-ring (7). If either part

is damaged, replace the part.
f. Inspect the filter cartridge for debris and

for damage. If necessary, replace the filter
cartridge.
4. Remove the filter element. Perform Step 4.a

through Step 4.f in order to remove the filter
element.
g00104510
Illustration 307
(8) Plate
(10) Shell
(11) O-ring
(12) Filter element
c. Hold the filter cartridge with one hand. Grasp

the grip of plate (8) with your other hand. Lift
plate (8) in order to separate plate (8) from the
filter cartridge.
g00104507
Illustration 305
d. Remove O-ring (11) from plate (8).
(4) Plug
(8) Plate
(18) O-ring e. Lift filter element (12) from shell (10).
a. Make sure that plug (4) is removed. Make sure f. Pour the remaining oil into a suitable container.
that all of O-ring (18) is removed from plate (8).
Note: Dispose of used oil according to local
regulations.
g. Repeat Step 4.a through Step 4.f for the other

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

5.a through Step 5.d in order to clean the shell of
the filter cartridge.
g00918893
Illustration 306
(8) Plate
(9) Spiral retaining ring
b. Remove spiral retaining ring (9).
g00104511
Illustration 308
(13) Slide plate
(14) Pads
(15) Screws
(19) Port
a. Turn shell (10) upside-down.

SEBU8044-01 175
Maintenance Section
b. Remove screws (15). j. Apply grease to new O-ring (18). Install O-ring
(18) on plug (4).
c. Remove Pads (14) from slide plate (13).
k. Install plug (4) into plate (8).
d. Wash the following parts in a clean
nonflammable solvent: plug (4), plate (8), spiral 7. Install the filter cartridge. Perform Step 7.a through
retaining ring (9), shell (10), and Pads (14). Dry Step 7.e in order to install the filter cartridge.
the parts.
6. Install the filter elements. Perform Step 6.a through

Step 6.k in order to install the filter elements.
Note: Consult a Caterpillar dealer for the Service Kit

that is needed to install the filter element and the
filter cartridge.
a. Apply spray type oil to the inside of shell (10) in

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

g00102220
Apply grease to this point. Illustration 310
(B) Port
d. Apply grease to O-rings inside ports (19) at the (C) Slide plate
bottom of shell (10).
a. Check that ports (B) at the bottom of the filter
e. Install new Pads (14). Tighten the screws to a case are closed.
torque of 0.4 N·m (3.5 lb in).
Note: If the ports are open, rotate slide plate (C)
f. Apply spray type oil into the clearance between counterclockwise to the stopper in order to fully
shell (10) and slide plate (13). close the ports. When the ports are fully closed, any
remaining oil in the filter case should be completely
removed.
g00104512
Illustration 309
(8) Plate g00102221
(10) Shell Illustration 311
(16) Boss (E) Slide plate
(17) Notch (D) Port
g. Turn over shell (10). Apply grease to the two b. Check that ports (D) of the filter cartridge are
O-rings on new element (12). Install element fully closed.
(12) into shell (10).
Note: The filter cartridge cannot be installed unless
h. Move boss (16) in alignment with notch (17). the ports are fully closed. If the ports are open, rotate
Install plate (8) into shell (10). slide plate (E) counterclockwise to the stopper in
order to fully close the ports.
i. Install spiral retaining ring (9) into the groove
in shell (10).
176 SEBU8044-01
Maintenance Section
Hydraulic System Oil Level - Check
i02438941
Hydraulic System Oil Level -

Check
SMCS Code: 5050-535
NOTICE
Never remove the fill/vent plug from the hydraulic tank
if the oil is hot.
Air can enter the system and cause pump damage.
g00102222
Illustration 312
(F) O-rings
c. Check that O-rings (F) have been installed and

that oil has been applied to O-rings (F).
g01218761
Illustration 314
The hydraulic tank is located on the right side of the machine.

bucket to the ground with the stick in a vertical
position, as shown.
g00102225
Illustration 313
(1) Bolts
d. Install the filter cartridge into the filter case.

Turn the filter cartridge clockwise by 180
degrees and push down the filter cartridge
when the filter cartridge contacts guide (A).
e. Install plug (4), cover (3), washers (2), and bolts

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

g01218776
Reference: For the correct procedure, refer to Illustration 315
Operation and Maintenance Manual, Hydraulic (A) High Temperature Range
System Oil Level - Check. (B) Low Temperature Range
2. For a cold machine, maintain the hydraulic oil level

in the low temperature range (B). For a machine
that is at normal operating temperature, maintain
the hydraulic oil level in the high temperature
range (A).
SEBU8044-01 177
Maintenance Section
Hydraulic System Oil Sample - Obtain
The hydraulic oil sampling valve is near the pilot filter.

Obtain a sample of the hydraulic oil from the hydraulic
oil sampling valve that is located on the hydraulic
oil filter housing. Refer to Special Publication,
SEBU6250, S·O·S 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.
i02439756
Hydraulic Tank Screen - Clean

Illustration 316
g01218607 SMCS Code: 5056-070-Z3

pertains to Containing Fluid Spillage.
Note: Perform Step 3 through Step 5 if the oil level

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

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

the O-ring seal if the O-ring seal is damaged.
5. Clean the fill/vent plug and install the fill/vent plug. Illustration 318 g01218672
i02438932 1. Park the machine on level ground. Lower the

Hydraulic System Oil Sample
- Obtain
SMCS Code: 5050-008-OC; 5095-008; 5095-SM;
7542-008; 7542
g01218797
Illustration 319
(1) Bolts
(2) Washers
(3) Cover
g01218735 2. Remove bolts (1), washers (2) and cover (3) from
Illustration 317
the top of the hydraulic tank.
178 SEBU8044-01
Maintenance Section
Hydraulic Tank Screen - Clean
7. Wash the screen in a clean nonflammable solvent.

Allow the screen to dry. Inspect the screen.
Replace the screen, if the screen is damaged.
g01218798
Illustration 320
(4) Fill/Vent plug
3. Clean the area thoroughly in order to keep dirt out g01218968

Illustration 322
of the screen cover. Clean the area thoroughly in (14) O-ring seal
order to keep dirt out of the fill/vent plug (4). (15) O-ring seal
4. Relieve the internal pressure from the hydraulic 8. Remove O-ring seal (14) from screen (13).
tank by loosening the fill/vent plug. After the
pressure is relieved, remove the fill/vent plug (4). 9. Inspect O-ring seals (14) and (15). Replace the
O-ring seals if wear or damage is evident.
10. Install O-ring seal (14) on screen (13).
11. Install screen (13) and spring (12). Then install

cover (11), washers (10), and bolts (9).
Note: Make sure that the O-ring seals and the spring
are properly positioned during installation.
12. Inspect the O-ring seal on the filler plug for

damage. Replace the O-ring, if necessary. Clean
the filler plug. Install the filler plug.
13. Install cover (3) with bolts (1) and washers (2).
14. Close the engine hood and latch the engine hood.
g01218966
Illustration 321
(9) Bolts
(10) Washers
(11) Cover
(12) Spring
(13) Screen
5. Remove bolts (9), washers (10) and cover (11).
Note: Do not allow spring (12) to fall into the tank.
6. Remove spring (12) and screen (13).
Note: Refer to Operation and Maintenance, General

Hazard Information for information on containing
fluid spillage.
SEBU8044-01 179
Maintenance Section
Indicators and Gauges - Test
i02116248 i02106227
Indicators and Gauges - Test Oil Filter - Inspect

SMCS Code: 7450-081; 7490-081 SMCS Code: 1308-507; 5068-507
Inspect a Used Filter for Debris
g01077750
Illustration 323
1. Look for broken lenses on the gauges, broken g00100013

Illustration 324
indicator lights, broken switches, and other broken
components in the cab. The element is shown with debris.
2. Start the engine. Use a filter cutter to cut the filter element open.
Spread apart the pleats and inspect the element for
3. Look for inoperative gauges. metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
4. Turn on all machine lights. Check for proper failure.
operation.
If metals are found in the filter element, a magnet can
5. Move the machine forward. Release the travel be used to differentiate between ferrous metals and
levers and the travel pedals. The machine should nonferrous metals.
stop.
Ferrous metals can indicate wear on steel parts and
6. Stop the engine. on cast iron parts.
7. Make any repairs that are required before Nonferrous metals can indicate wear on the
operating the machine. aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.
Small amounts of debris may be found in the filter

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

by Caterpillar can result in severe engine damage
to engine bearings, to the crankshaft, and to other
parts. This can result in larger particles in unfiltered
oil. The particles could enter the lubricating system
and the particles could cause damage.
180 SEBU8044-01
Maintenance Section
Quick Coupler - Lubricate
i02461929
Quick Coupler - Lubricate

(If Equipped)
SMCS Code: 6129-086
Note: Caterpillar recommends the use of

5% molybdenum grease. Refer to Special
Publication, SEBU6250, Caterpillar Machine
molybdenum grease.
g01164506
Illustration 326
3. Remove four pins (3).
4. Remove screens (2) and (4).
5. Check all of the core fins for debris.

g00104878
Illustration 325 6. Remove dust and debris from all of the core fins
Typical Example and from the screens.
Apply lubricant through the four fittings on the quick Compressed air is preferred, but high pressure
coupler. The quick coupler has two fittings on each water or steam can be used to remove dust and
side. general debris from a core.
Note: Do not lubricate the wedge and the wear See Special Publication, SEBD0518, Know Your
plates. Friction is needed in order to hold the wedge Cooling System for more detailed information
in place during backfilling. about cleaning core fins.
7. Install screens (2) and (4) with pins (3).

i02430101
8. Close the rear access door on the left side of the
Radiator Core - Clean machine.
SMCS Code: 1353-070
9. Close the hood.
1. Open the hood.
2. Open the rear access door on the left side of the

machine.
SEBU8044-01 181
Maintenance Section
Refrigerant Dryer - Replace
i02252730 i02429589
Refrigerant Dryer - Replace Seat Belt - Inspect

SMCS Code: 7322-510 SMCS Code: 7327-040
Always check the condition of the seat belt and the

condition of the seat belt mounting hardware before
Personal injury can result from contact with refrig- you operate the machine. Replace any parts that are
erant. damaged or worn before you operate the machine.
Contact with refrigerant can cause frost bite. Keep

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

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

Slowly loosen the fitting. If the system is still un-
der pressure, release it slowly in a well ventilated
area.
Personal injury or death can result from inhaling

refrigerant through a lit cigarette. g00932801
Illustration 327
Inhaling air conditioner refrigerant gas through a Typical example

lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air con- Check the seat belt mounting hardware (1) for wear
ditioner refrigerant gas, can cause bodily harm or or for damage. Replace any mounting hardware that
death. is worn or damaged. Make sure that the mounting
bolts are tight.
Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present. Check buckle (2) for wear or for damage. If the buckle
is worn or damaged, replace the seat belt.
Use a certified recovery and recycling cart to prop-
erly remove the refrigerant from the air condition- Inspect the seat belt (3) for webbing that is worn or
ing system. frayed. Replace the seat belt if the seat belt is worn
or frayed.
NOTICE Consult your Caterpillar dealer for the replacement of

If the refrigerant system has been open to the outside the seat belt and the mounting hardware.
air (without being plugged) for more than 30 minutes,
the receiver-dryer must be replaced. Moisture will en- Note: Within three years of the date of installation or
ter an open refrigerant system and cause corrosion within five years of the date of manufacture, replace
which will lead to component failure. the seat belt. Replace the seat belt at the date which
occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
Refer to Service Manual, SENR5664, Air buckle, and the seat belt retractor.
Conditioning and Heating System with R-134a
Refrigerant for All Caterpillar Machines for the proper If your machine is equipped with a seat belt
procedure to change the receiver-dryer assembly extension, also perform this inspection procedure for
and for the procedure to reclaim the refrigerant gas. the seat belt extension.
182 SEBU8044-01
Maintenance Section
Seat Belt - Replace
i02429594
Seat Belt - Replace

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

five years of the date of manufacture, replace the
seat belt . Replace the seat belt at the date which
occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.
g01218090
Illustration 329
The swing bearing is located under the base of the

boom.
g01152685
Illustration 328
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Date of manufacture (tag) (fully extended web)
(4) Date of manufacture (underside) (buckle)
Consult your Caterpillar dealer for the replacement of

the seat belt and the mounting hardware.
g00687903
If your machine is equipped with a seat belt Illustration 330
extension, also perform this replacement procedure
for the seat belt extension. Apply lubricant through the fittings until the lubricant
overflows the bearing seals.
i02437876
i02437912
Swing Bearing - Lubricate
Swing Drive Oil - Change
SMCS Code: 7063-086
SMCS Code: 5459-044
Note: Refer to Special Publication, SEBU6250,
Caterpillar Machine Fluids Recommendations for
more information on 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 fittings before you lubricate the swing

bearing.
g01218123
Illustration 331
SEBU8044-01 183
Maintenance Section
Swing Drive Oil Level - Check
The oil drain hose is under the center of the upper

structure.
g00687983
Illustration 334
g00687981 4. Remove dipstick (4).

Illustration 332
Note: Refer to Operation and Maintenance Manual, 5. Add the specified quantity of oil through the
General Hazard Information for information that dipstick tube. See Operation and Maintenance,
pertains to Containing Fluid Spillage. Capacities (Refill).
1. Remove drain hose (2) from holder (1) on the 6. Check the oil level. Refer to Operation and
upper frame. Face the end of the hose toward the Maintenance Manual, Swing Drive Oil Level -
container. Check for the procedure.
2. Use a universal joint with a socket extension to 7. Check the oil that has been drained for metal chips
loosen the drain valve in hole (3). Drain the oil into or metal particles. Consult your Caterpillar dealer
a suitable container. if any metal chips or metal particles are found.
Note: Drained fluids should always be disposed of 8. Drained materials should always be disposed of
according to local regulations. according to local regulations.
i02437927
Swing Drive Oil Level - Check

g00687982
Illustration 333
3. Tighten the drain valve. Hook the drain hose (2)

to the holder (1). Make sure that the end of the
hose is facing upward.
g01218136
Illustration 335
The dipstick for the swing drive oil is on the swing

drive at the rear base of the boom.
184 SEBU8044-01
Maintenance Section
Swing Drive Oil Sample - Obtain
i01870162
Swing Drive Oil Sample -

Obtain
SMCS Code: 5459-008; 5459-008-OC;
5459-554-OC; 5459-OC; 7542-008
g00684917
Illustration 336
1. Remove the dipstick.
g00684917
Illustration 338
Obtain an oil sample of the swing drive oil through the

opening for the dipstick. Refer to Special Publication,
SEBU6250, S·O·S Oil Analysis for information
that pertains to obtaining an oil sample from the
swing drive housing. Refer to Special Publication,
PEHP6001, How To Take A Good Oil Sample for
more information about obtaining an oil sample from
the swing drive housing.
g01049757
Illustration 337
i01963879
General Hazard Information for information that Swing Gear - Lubricate
pertains to Containing Fluid Spillage.
SMCS Code: 7063-086
2. Check the dipstick. Maintain the oil level between
the marks on the dipstick. Add oil through the Note: Refer to Special Publication, SEBU6250,
dipstick tube, if necessary. Refer to Operation Caterpillar Machine Fluids Recommendations for
and Maintenance Manual, Lubricant Viscosities more information on grease.
when you select an oil. If the oil level is above
the FULL line, then remove oil from the system. NOTICE
Restore the oil to the correct level position. Improper lubrication can cause damage to machine
components.
3. Insert the dipstick.
To avoid damage, make sure that the proper amount
of grease is applied to the swing drive.
When the amount of grease in the compartment be-

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

gear of the swing drive and swing internal gear.
Not enough grease will result in poor gear lubrication.

SEBU8044-01 185
Maintenance Section
Swing Gear - Lubricate
2. Inspect gasket (4). Replace the gasket if damage

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

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

Capacities (Refill) for the size of the pan.
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.
g00688052
Illustration 339
Remove the inspection cover that is located near the

boom base. Inspect the grease.
g00688063
Illustration 342
(5) Bolts
(6) Washers
(7) Cover
(8) Gasket
g00688056
Illustration 340
(1) Bolts 4. Check for contamination and for discolored
(2) Washers grease.
(3) Cover
(4) Gasket 5. If the grease is contaminated or discolored with
water, change the grease. Remove bolts (5),
1. Remove bolts (1) and washers (2). Remove cover washers (6), cover (7), and gasket (8) in order
(3) and gasket (4). to allow the water to drain. When you reinstall
cover (7), inspect gasket (8). Replace the gasket
if damage is evident.
g00688058
Illustration 341
(3) Cover
(4) Gasket Illustration 343 g00101644
186 SEBU8044-01
Maintenance Section
Track Adjustment - Adjust
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).
i02255665
Track Adjustment - Adjust

SMCS Code: 4170-025
g01103855
Illustration 344
2. Stop with one track pin directly over the front

Personal injury or death can result from grease carrier roller. Park the machine and turn off the
under pressure. engine.
Grease coming out of the relief valve under pres-

sure can penetrate the body causing injury or
death.
Do not watch the relief valve to see if grease is es-

caping. Watch the track or track adjustment cylin-
der to see if the track is being loosened.
Loosen the relief valve one turn only.
If track does not loosen, close the relief valve and

contact your Caterpillar dealer.
g00101752
NOTICE Illustration 345
Keeping the track properly adjusted will increase the
service life of the track and drive components. 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
Note: The track tension must be adjusted according the front carrier roller to the idler.
to the current operating conditions. Keep the track as
slack as possible if the soil is heavy.
4. Measure the maximum amount of sag in the track.
The sag is measured from the highest point of the
Measuring Track Tension track grouser to the bottom of the straight edge. A
track that is properly adjusted will have a sag of
1. Operate the machine in the direction of the idlers. 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.
SEBU8044-01 187
Maintenance Section
Track Adjustment - Inspect
Loosening the Track
g00270405
Illustration 346
The track adjuster is located on the track frame. g01091134
Illustration 348
(1) Grease fitting
Tightening the Track (2) Relief valve
1. Loosen relief valve (2) carefully until the track

begins to loosen. One turn should be the
maximum.
2. Tighten relief valve (2) to 34 ± 5 N·m (25 ± 4 lb ft)

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

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

needed.
If the correct adjustment cannot be achieved, consult

Illustration 347
g01091134 your Caterpillar Dealer.
(1) Grease fitting
(2) Relief valve i01590290
Wipe the fitting before you add grease. Track Adjustment - Inspect
1. Add grease through grease fitting (1) until the SMCS Code: 4170-040
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 349
Check the track adjustment. Check the track for wear

and for excessive dirt buildup.
188 SEBU8044-01
Maintenance Section
Travel Alarm - Test
If the track appears to be too tight or too loose,

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

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

alarm.
g01126167
1. Start the engine. Move the hydraulic lockout Illustration 351
control to the UNLOCKED position.
6. Push the alarm cancel switch. The travel alarm
2. Raise the work tool in order to avoid any obstacles. should shut off.
Make sure that there is adequate overhead
clearance. 7. Stop the machine. Lower the work tool to the
ground. Move the Hydraulic lockout control to the
LOCKED position. Stop the engine.
i00059532
Undercarriage - Check
SMCS Code: 4150-535
g00560313
Illustration 350
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.
g00101898
Illustration 352
5. Use the travel levers and the travel pedals to
move the machine backward. The travel alarm 1. Check the carrier rollers, the track rollers, and the
should sound. 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.
SEBU8044-01 189
Maintenance Section
Window Washer Reservoir - Fill
i01458697 i01077829
Window Washer Reservoir - Windows - Clean

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

machine.
g00566124
Illustration 354
Typical example
Use a pole with a squeegee in order to reach the high

areas of the window.
g00688996
Illustration 353
2. Remove the filler cap.

Cleaning Methods
3. Fill the window washer reservoir with washer fluid Aircraft Windshield Cleaner
through the filler opening.
Apply the cleaner with a soft cloth. Rub the window
4. Install the filler cap. with moderate pressure until all the dirt is removed.
Allow the cleaner to dry. Wipe off the cleaner with a
5. Close the access door. clean soft cloth.
Soap and Water

i01258249
Window Wiper - Use a clean sponge or a soft cloth. Wash the windows
with a mild soap or with a mild detergent. Also
Inspect/Replace use plenty of lukewarm water. Rinse the windows
thoroughly. Dry the windows with a moist chamois or
SMCS Code: 7305-040; 7305-510 with a moist cellulose sponge.
Inspect the condition of the wiper blades. Replace Stubborn Dirt and Grease
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.
L36
321-BR-18
235-BK 200-BK -18
M740-P K-18
763-BU-18 506-PU-18
M737-WH-18
L36 L36
M738-OR-18 200-BK -18
788-YL-18 235-BK -18 954-GN 1
M739-Y L-18 K 849-Y L-18 200-BK -18 2
A 762-P U-18 954-GN
492-GY-18 200-BK -18
495-GN-18
A 761-P U-18 578-BU
K 904-GN-18
491-PK -18 506-PU-18
T967-YL-18 578-BU K 849-Y L-18 1
496-WH-18 200-BK 235-BK -18 2
C468-B U-18 235-BK -18
405-GY-18 235-BK -18 G976-BU-18 235-BK -18
487-OR-18 412-BU-18 147-PU 412-BU-18
L34 L34
403-GN-18 430-BU-18 506-PU-18
403-GN-18 G976-BU-18 578-BU
403-GN-18 147-PU 412-BU-18
403-GN-18 200-BK -14 200-BK
403-GN-18 168-RD-10 200-BK 147-PU A +B
147-PU 101-RD-4 200-BK -18 235-BK -18 B GROUND
147-PU 877-YL-4 200-BK -18 G976-BU-18 C S IGNA L
147-PU 109-RD-6 235-BK -18
147-PU 304-WH-8 235-BK -18
147-PU 189-RD 235-BK -18
L973-GN-18 147-PU A 588-GN 235-BK -18
K 906-GN-18 235-BK -18 L975-PK -18 430-BU-18
A 588-GN 200-BK -14 184-RD 235-BK -18 235-BK -18
763-BU-18 200-BK -18 K 776-GN-18 430-BU-18
M740-P K-18 200-BK -14 A 718-P U-18
200-BK -18 200-BK -14 403-GN-18
200-BK -18 K 906-GN-18 309-GY-18
235-BK -18 A 588-GN 616-BU
235-BK -18 200-BK 322-GY
235-BK -18 235-BK -18 607-PK
200-BK -18 235-BK -18 235-BK -18 893-GN-18
235-BK -18 200-BK -18 101-RD-4 893-GN-18
235-BK -18 200-BK -18 877-YL-4 893-GN-18
235-BK -18 200-BK -14 109-RD-6 893-GN-18
235-BK -18 200-BK -18 304-WH-8 893-GN-18
235-BK -18 200-BK -14 189-RD 892-BR-18
200-BK -14 200-BK -14 K 776-GN-18 892-BR-18
200-BK 200-BK -18 235-BK -18 A 718-P U-18 892-BR-18
A 718-P U-18 200-BK -14 235-BK -18 309-GY-18 892-BR-18
492-GY-18 200-BK -14 235-BK 616-BU 892-BR-18
309-GY-18 200-BK -18 235-BK -18 322-GY 892-BR-18
K 776-GN-18 200-BK -18 235-BK -18 607-PK 893-GN-18
109-RD-6 235-BK 235-BK -18 A 768-B U-18 H474-G N-18
403-GN-18 200-BK 200-BK A 769-GY-18 H475-B U-18
E 554-P K-18 200-BK 788-YL-18 F774-WH-18 H476-WH-18
L32
304-WH-8 200-BK A 762-P U-18 F773-OR-18 K 851-B U-18
101-RD-4 235-BK 492-GY-18 E 554-P K-18 K 849-Y L-18
405-GY-18 200-BK -10 A 761-P U-18 168-RD-10 K 852-GN-18
C468-B U-18 235-BK -18 C468-B U-18 780-PU-18 L972-BU-18
L23
308-YL 235-BK -18 405-GY-18 L973-GN-18 M736-B U-18
F774-WH-18 235-BK -18 101-RD-4 M736-B U-18 M736-B U-18
F773-OR-18 235-BK -14 877-YL-4 308-YL M736-B U-18
A 761-P U-18 235-BK -18 109-RD-6 308-YL M736-B U-18
189-RD 304-WH-8 308-YL M736-B U-18
M736-B U-18 189-RD 308-YL K 906-GN-18
877-YL-4 L33 L33 L33 L33 K 776-GN-18 M736-B U-18 A 768-B U-18
788-YL-18 A 718-P U-18 M736-B U-18 A 769-GY-18
A 762-P U-18 309-GY-18 L973-GN-18 308-YL
235-BK -18 F774-WH-18 893-GN-18 L973-GN-18
235-BK -18 F773-OR-18 893-GN-18 L973-GN-18
200-BK 403-GN-18 892-BR-18 L973-GN-18
200-BK E 554-P K-18 892-BR-18 L973-GN-18
L32 L32 L32
200-BK 308-YL 412-BU-18 F774-WH-18
235-BK M736-B U-18 430-BU-18 F773-OR-18
200-BK -10 M737-WH-18 L975-PK -18 A 755-P K-18
616-BU M738-OR-18 184-RD A 756-B U-18
322-GY M739-Y L-18 H474-G N-18 A 757-GY-18
L2 L31 L31 L31 L31
607-PK 495-GN-18 H475-B U-18 A 758-B R-18
495-GN-18 K 904-GN-18 H476-WH-18 K 907-B U-18
321-BR-18 491-PK -18 K 851-B U-18 L969-WH-18
487-OR-18 T967-YL-18 K 849-Y L-18 L968-OR-18
491-PK -18 496-WH-18 K 852-GN-18 410-WH-18
496-WH-18 487-OR-18 L972-BU-18 M741-GY-18
A 768-B U-18 321-BR-18 A 755-P K-18 H465-G N-18
A 769-GY-18 616-BU A 756-B U-18 M742-P U-18
200-BK -18 147-PU 322-GY A 757-GY-18 H466-B U-18
200-BK -6 147-PU 607-PK A 758-B R-18 M734-B R-18
200-BK K 904-GN-18 A 768-B U-18 K 907-B U-18 H467-WH-18
T967-YL-18 A 769-GY-18 L969-WH-18 403-GN-18
M737-WH-18 147-PU L968-OR-18 E 554-P K-18
M738-OR-18 147-PU 410-WH-18 147-PU
M739-Y L-18 780-PU-18 M741-GY-18 200-BK -18
780-PU-18 168-RD-10 H465-G N-18 200-BK -14
168-RD-10 M742-P U-18 200-BK -14
H466-B U-18 780-PU-18
L26
M734-B R-18 H473-B R-18
H467-WH-18 235-BK -18
G976-BU-18 578-BU
H473-B R-18 506-PU-18
L23 L23 L23 L29

L24 L24 L21
L25 L25
K 849-Y L-18
130-RD-14 1 +B M740-P K-18 1 TRAV EL STRA IGHT SOL

235-BK -14 2 GND 763-BU-18 2 TRAV EL SP EE D CHANGE S OL
3 3
4 K 907-B U-18 4 S WING B RAK E CANCE L SOL
5 5 HEA TER RE LAY /S TA RTE R RELAY
6 L973-GN-18 6 FRE E SWI NG S W
7 L969-WH-18 7 P OWER SHIF T CONTROL P RV
8 M737-WH-18 8 FLOW LIM IT PRE SS P RV
A 308-YL 9 ATCH T OOL S W (1) M738-OR-18 9 P RI MA RY NF C PRE SS P RV
B 235-BK -18 10 ATCH T OOL S W (2) 10 FAN MOT OR CONTROL P RV
C E 470-B R-18 1 M738-OR-18 K 843-GN-18 11 RIGHT J OYS TICK S W (1) 11 OP TIO N CONTROL P RV
2 M739-Y L-18 K 847-P U-18 12 RIGHT J OYS TICK S W (2) 12 OP TIO N CONTROL P RV
130-RD-14 13 +B 321-BR-18 13 TRAV EL A LARM 1 320-RD-18
235-BK -14 14 GND 235-BK H466-B U-18 14 A EC M ODE IND 2 A 770-P K-18
15 235-BK H467-WH-18 15 TRAV EL MODE IND 3 645-RD-18
16 235-BK 788-YL-18 16 S PE ED S E NS OR (-) 4 615-YL
17 235-BK 17 FI NE SWI NG S W 5 189-RD 168-RD-10
A 308-YL 18 M740-P K-18 18 6 152-BU 150-OR-18
1 L16
B 235-BK -18 M737-WH-18 19 ATCH T OOL S W (3) 763-BU-18 L968-OR-18 19 P RV RE TURN (1) 7 105-RD 607-PK
C E 471-B U-18 2 M739-Y L-18 20 ATCH T OOL S W (4) M737-WH-18 M739-Y L-18 20 P RV RE TURN (2) 8 129-BU A 587-Y L
K 844-GY-18 21 LEF T J OY STI CK SW (1) M738-OR-18 21 P RV RE TURN (3) 9 123-WH-18 105-RD
K 848-WH-18 22 LEF T J OY STI CK SW (2) 788-YL-18 22 P RV RE TURN (4) 10 154-RD 189-RD
308-YL 23 K EY S W 321-BR-18 410-WH-18 23 FAULT A LARM 11 308-YL 645-RD-18
24 M739-Y L-18 H465-G N-18 24 TRAV EL A LARM CANCE L IND 12 151-GN 615-YL
25 A 762-P U-18 A 762-P U-18 25 S PE ED S E NS OR (+) 103-RD
26 492-GY-18 26 OP TIO N VO LTAG E SW (1) 175-RD-14
1 K 853-GY-18 27 495-GN-18 27 152-BU
2 K 867-Y L-18 28 S ENSO R RET 403-GN-18 28 118-GY
29 A 761-P U-18 492-GY-18 29 COOLA NT TE MP S ENS OR L19 L19 1 175-RD-14 191-WH-14
30 S WITCH RE T K 904-GN-18 495-GN-18 30 FUE L LEV EL 2 120-YL 147-PU
31 OP TIO N SW (4) 491-PK -18 31 A NA LOG SE NSOR RE TURN 3 124-GN-14 113-OR-18
32 OP TIO N SW (3) T967-YL-18 32 4 179-BU 124-GN-14
893-GN-18 33 CAT LINK + 496-WH-18 33 5 307-OR 123-WH-18
34 RS-232 RX C468-B U-18 34 6 147-PU 120-YL
35 RS-232 T X 405-GY-18 403-GN-18 35 A LTE RNATOR R TERM . 7 607-PK 179-BU 200-BK -18
1 K 854-OR-18 36 487-OR-18 A 761-P U-18 36 GOV ERNOR F EE DBA CK 8 103-RD 129-BU 200-BK -18
2 K 867-Y L-18 37 K 851-B U-18 K 904-GN-18 37 P UM P DIS CHA RGE(1) P RES S SE NSOR 9 169-PK -18 320-RD-18 200-BK
38 K 851-B U-18 38 10 113-OR-18 151-GN 200-BK -14
39 K 851-B U-18 491-PK -18 39 HYD OIL T EM P SE NS OR 11 646-RD-18 307-OR 200-BK -18
40 S W RET K 849-Y L-18 40 S ENSO R RET 12 154-RD 235-BK -18
41 OP TIO N SW (2) K 850-B R-18 41 646-RD-18 200-BK -18
42 OP TIO N SW (1) K 852-GN-18 42 646-RD-18 200-BK -18
892-BR-18 43 CAT LINK - K 852-GN-18 43 1 118-GY 646-RD-18 200-BK -18
44 RS-232 G ND K 852-GN-18 M736-B U-18 44 GOV ERNOR COM MA ND 2 150-OR-18 646-RD-18 200-BK -18
45 K 852-GN-18 T967-YL-18 45 P UM P DIS CHA RGE(2) P RES S SE NSOR 3 191-WH-14 308-YL
1 K 863-OR-18 46 L973-GN-18 46 O. L.W.D. P RE SS S E NS OR 4 A 587-Y L 169-PK -18
2 K 869-B U-18 47 893-GN-18 M736-B U-18 47 B ACKUP S W A 770-P K-18
48 892-BR-18 48 OP TIO N PWM I N (1)
49 K 907-B U-18 49
C
50 L969-WH-18 50 168-RD-10
51 H466-B U-18 51
DD
52 H467-WH-18 52 +12V S UP PLY 877-YL-4
KK
151-GN 53 HYD LOCK CA NCEL S W L968-OR-18 53 101-RD-6
EE
1 K 859-B R-18 54 MA S K ENAB LE 410-WH-18 54 101-RD-4 101-RD-4
LL
2 K 869-B U-18 H465-G N-18 109-RD-6
G976-BU-18 MM 109-RD-8
892-BR-18 K 866-WH-18 1 1WAY/ 2WAY CHA NGE S OL M736-B U-18 184-RD 1 +B 200-BK -14
NN
893-GN-18 K 874-B R-18 2 VA RIA BLE RELI EF 1 CHE CK SOL M736-B U-18 235-BK 2 GND 304-WH-8 151-GN
K 849-Y L-18 K 875-B U-18 3 VA RIA BLE RELI EF 2 CHE CK SOL L975-PK -18 3 K 776-GN-18
K 850-B R-18 4 K 852-GN-18 L975-PK -18 4 A IR HE ATE R CONTROLLER 403-GN-18
K 851-B U-18 5 K 851-B U-18 5 A UT O LUB FAI LURE 893-GN-18
1 K 862-GY-18 K 852-GN-18 6 K 849-Y L-18 6 S WITCH RE TURN 1 L975-PK -18 892-BR-18
2 K 869-B U-18 130-RD-14 K 855-P K-18 7 S EPA RATE VA LV E PRV A 755-P K-18 7 OP TIO N SW 2 184-RD 616-BU
L26
130-RD-14 K 860-B U-18 8 ATT S TEM 1 RETRA CT P RV A 756-B U-18 8 OP TIO N SW 3 K 776-GN-18 607-PK
130-RD-14 K 858-Y L-18 9 ATT S TEM 3 EX TE ND PRV L972-BU-18 A 755-P K-18 9 THROTT LE POS ITI ON 1 L28 L28 4 A 718-P U-18 130-RD-14 877-YL-4
130-RD-14 K 863-OR-18 10 ATT S TEM 4 RETRA CT P RV M742-P U-18 A 756-B U-18 10 THROTT LE POS ITI ON 2 5 403-GN-18 184-RD
151-GN 11 A 757-GY-18 L972-BU-18 11 ONE TOUCH LOW IDLE S W 6 322-GY
E 472-GN-18 K 864-P K-18 12 VA RIA BLE RELI EF 1 PRV A 758-B R-18 M742-P U-18 12 A EC M ODE SW A 588-GN
E 473-GY-18 K 849-Y L-18 13 ATT S TEM 1 STATUS M734-B R-18 184-RD 13 +B 189-RD
1 K 858-Y L-18 E 474-OR-18 K 852-GN-18 14 ATT S TEM 4 STATUS M741-GY-18 235-BK 14 GND 1 200-BK -14 309-GY-18
2 K 869-B U-18 K 843-GN-18 15 308-YL 15 2 309-GY-18 308-YL
K 844-GY-18 16 OP TIO N PWM S ENS OR (1) H476-WH-18 16 OV ER LO AD A LARM CANCE L SW 3 616-BU A 718-P U-18
K 847-P U-18 17 H475-B U-18 17 CREE PE R TRAV EL FUNCT ION S W 4 322-GY L975-PK -18
K 848-WH-18 K 857-WH-18 18 ATT S TEM 2 EX TE ND PRV H474-G N-18 K 850-B R-18 18 ATCH STE M2 SWI NG CA NCE L 5 607-PK
K 855-P K-18 K 862-GY-18 19 ATT S TEM 3 RETRA CT P RV 184-RD A 757-GY-18 19 THROTT LE POS ITI ON 3 6 893-GN-18
E 469-Y L-18 20 184-RD A 758-B R-18 20 THROTT LE POS ITI ON 4 7 892-BR-18 310-PU-18
E 475-P K-18 21 184-RD M734-B R-18 21 TRAV EL MODE SW 8 189-RD 200-BK -18
1 K 861-GN-18 E 476-P U-18 K 865-P U-18 22 VA RIA BLE RELI EF 2 PRV 184-RD M741-GY-18 22 TRAV EL A LARM CANCE L SW 9 A 588-GN
2 K 868-B R-18 235-BK -14 K 851-B U-18 23 ATT S TEM 3 STATUS 430-BU-18 308-YL 23 K EY S W ON 10 200-BK -18
235-BK -14 24 412-BU-18 24 11
235-BK -14 E 469-Y L-18 25 S EPA RATE LOA D PRE SS . SE NSOR H473-B R-18 K 849-Y L-18 25 12
235-BK -14 E 474-OR-18 26 LEF T J OY STI CK THUMB WHEE L 893-GN-18 K 849-Y L-18 26 112-P U-6
K 867-Y L-18 27 892-BR-18 K 849-Y L-18 27
308-YL K 856-P U-18 28 ATT S TEM 1 EX TE ND PRV K 849-Y L-18 28 ATCH STE M1 SWI NG CA NCE L A 130-RD-14
L29
308-YL K 861-GN-18 29 ATT S TEM 2 RETRA CT P RV H476-WH-18 29 J OYS TI CK P RES S SW B 308-YL
1 K 857-WH-18 1 A 768-B U-18 308-YL K 859-B R-18 30 ATT S TEM 4 EX TE ND PRV 1 892-BR-18 H475-B U-18 30 TRAV EL LE FT PRE SS S W C 151-GN
2 K 868-B R-18 2 A 769-GY-18 308-YL 31 2 893-GN-18 412-BU-18 31 COOLA NT LE VE L SW 101-RD-6
K 867-Y L-18 32 3 K 849-Y L-18 496-WH-18 32 HYD OIL LE V EL S W 101-RD-6
K 867-Y L-18 K 850-B R-18 33 ATT S TEM 2 STATUS 4 K 850-B R-18 893-GN-18 33 CAT DA TA LI NK (+) 308-YL
308-YL 34 5 K 851-B U-18 34 308-YL
K 856-P U-18 E 470-B R-18 35 P UM P1 NEG CONT P RES S. S ENS OR 6 K852-GN-18 35 308-YL
+B Y L-18 A 147-PU K 857-WH-18 E 473-GY-18 36 RIGHT J OYS TICK THUM B WHE E L 36 A 308-YL
GROUND B K-18 B 235-BK -18 K 858-Y L-18 E 476-P U-18 37 RIGHT FOOT P EDAL 37 B 308-YL-18
L37
1 K 860-B U-18 S IGNA L B R-18 C K 904-GN-18 K 859-B R-18 K 867-Y L-18 38 P RV RE T 38 FUE L PRI MA RY F ILTER PLUGGE D C
2 K 868-B R-18 K 860-B U-18 K 868-B R-18 39 P RV RE T H474-G N-18 39 TRAV EL RI GHT P RES S SW 169-PK -18
L17 L17
K 861-GN-18 K 869-B U-18 40 P RV RE T C468-B U-18 40 E NG OI L LEV EL SW 169-PK -18
K 862-GY-18 K 870-GN-18 41 P RV RE T 405-GY-18 41 E NG OI L PRE SS S W A 770-P K-18
K 863-OR-18 42 P RV RE T 1 487-OR-18 42 CAP SULE F ILTER PLUGGE D 308-YL-18
K 868-B R-18 43 2 892-BR-18 43 CAT DA TA LI NK (-) 308-YL-18 K EY S W. (ON)
K 869-B U-18 44 3 44 A 718-P U-18 TE MP.
+B Y L-18 A 147-PU E 470-B R-18 E 471-B U-18 45 P UM P2 NEG CONT P RES S. S ENS OR 4 K 851-B U-18 45 ATCH STE M3 SWI NG CA NCE L L975-PK -18 INDI CA TOR
1 K 856-P U-18 GROUND B K-18 B 235-BK -18 E 471-B U-18 E 475-P K-18 46 LEF T F OOT P E DA L 5 K 852-GN-18 46 ATCH STE M4 SWI NG CA NCE L 310-PU-18 RELAY
2 K 868-B R-18 S IGNA L B R-18 C T967-YL-18 K 853-GY-18 K 853-GY-18 47 P UM P1 NFC RE DUCE P RV 6 G976-BU-18 47 WATE R S EPA RATOR LE VE L S W 200-BK -18 REG ULAT OR
K 854-OR-18 K 854-OR-18 48 P UM P2 NFC RE DUCE P RV 430-BU-18 48 A IR CLE ANE R PLUGGE D 200-BK -18 CHECK TE RM.
K 870-GN-18 49 49 200-BK -18 GND
K 864-P K-18 50 50 306-GN K EY S W. (START)
K 865-P U-18 51 51 FUE L SE CONDARY FILTE R P LUG GED 306-GN
K 866-WH-18 52 P RV RE T 52 S PE CI AL FILTE R P LUG GED
K 874-B R-18 53 H473-B R-18 53 TRAV EL STRA IGHT PRE SS S W
K 875-B U-18 E 472-GN-18 54 12V PO WER S UPP LY 54
L35
GROUND BK 1 235-BK -18 L21

S IGNA L RD 2 487-OR-18
491-PK -18 135-BU-14

235-BK -18 210-BK -14
C569-Y L-14
1 496-WH-18 229-BK -14
2 235-BK -18
1 113-OR-18
2 200-BK -18
3 509-WH-18
5 512-GN-18
6 607-PK
7 103-RD
8 508-PU-18
L35
10 511-B R-18
4 C566-P K -18 L13
BK 2 235-BK -18 9 C560-O R-18 200-BK -18
L22
YL 1 495-GN-18 200-BK
L12
200-BK
200-BK -14
200-BK
L19 L19
201-BK -18
L18 L18
325-PK -18 1 325-PK -18
2 135-BU-14
210-BK -14
1 509-WH-18 C569-Y L-14 200-BK
2 508-PU-18 229-BK -14 201-BK -18
3 200-BK -18 607-PK A 584-B U-18
7 512-GN-18 509-WH-18 508-PU-18
8 511-B R-18 512-GN-18 509-WH-18
4 509-WH-18 508-PU-18 511-B R-18
5 A 513-RD-18 512-GN-18 511-B R-18 512-GN-18
1 321-BR-18 6 592-BU-18 508-PU-18 103-RD 607-PK -18
2 235-BK -18 511-B R-18 113-OR-18 607-PK 1 403-GN-18
200-BK -18 200-BK -18 607-PK 2 410-WH-18
200-BK -18 K 871-WH 200-BK -14 3 506-PU-18
ME M A 513-RD-18 200-BK -18 K 872-OR 103-RD 4 578-BU
12V 592-BU-18 200-BK -18 K 879-GN 607-PK 5 535-BU
24V 103-RD-18 200-BK -18 607-PK -18 615-YL 6 152-BU
IG N 113-OR-18 113-OR-18 307-OR 615-YL 7 129-BU
GND 200-BK -18 103-RD-18 310-PU 607-PK 8 645-RD-18
586-BR 103-RD 9 892-BR-18
147-PU 103-RD 10 893-GN-18
147-PU 103-RD 11 103-RD
147-PU 103-RD 12 235-BK -18
147-PU 103-RD
1 K 875-B U-18 607-PK -18 147-PU 200-BK -14 1 H465-G N-18
2 235-BK -18 607-PK -18 147-PU 113-OR-18 2 M742-P U-18
K 871-WH L973-GN 113-OR-18 3 586-BR-18
200-BK -18 113-OR-18 4 113-OR-18
147-PU 200-BK -18 113-OR-18 5 575-YL-18
200-BK -18 607-PK -18 K 871-WH 6 A 537-P K-18
200-BK -18 607-PK -18 K 872-OR 7 H466-B U-18
200-BK -18 K 879-GN 8 H467-WH-18
200-BK -18 129-BU 9 615-YL
1 K 865-P U-18 A 537-P K-18 307-OR 10 646-RD-18
2 K 870-GN-18 607-PK -18 578-BU 310-PU 11 M734-B R-18
607-PK -18 575-YL-18 586-BR 12 118-GY
K 872-OR 576-PK -18 147-PU 13 169-PK -18
K 879-GN 123-WH-18 A 537-P K-18 14 M741-GY-18
535-BU-18 578-BU 15
147-PU 535-BU-18 152-BU 16
200-BK -18 535-BU 575-YL-18 17
200-BK -18 535-BU 576-PK -18 18
1 K 866-WH-18 535-BU 123-WH-18
2 235-BK -18 607-PK -18 200-BK -18 646-RD-18 1 C569-Y L
607-PK -18 607-PK 645-RD-18 2 229-BK
307-OR 646-RD-18 M741-GY-18 3 L973-GN-18
310-PU 645-RD-18 H465-G N-18 4 K 871-WH-18
200-BK -18 113-OR-18 M742-P U-18 5 K 872-OR-18
200-BK -18 M741-GY-18 H466-B U-18 6 K 879-GN-18
H465-G N-18 M734-B R-18 7 191-WH-14
M742-P U-18 H467-WH-18 8 A 587-Y L
1 K 874-B R-18 607-PK -18 H466-B U-18 403-GN-18 9
2 235-BK -18 607-PK -18 M734-B R-18 410-WH-18 10
586-BR H467-WH-18 506-PU-18 11
147-PU 129-BU 118-GY 12 200-BK -14
403-GN-18 169-PK -18 13 607-PK
200-BK -18 410-WH-18 893-GN-18 14 200-BK -14
200-BK -18 A 584-B U-18 892-BR-18 15 307-OR
506-PU-18 200-BK -14 16 310-PU
1 K 864-P K-18 607-PK -18 118-GY 535-BU 17 576-PK -18
2 K 870-GN-18 607-PK -18 200-BK -14 535-BU 18 147-PU
L973-GN 169-PK -18 535-BU 19 123-WH-18
103-RD 535-BU 20 135-BU
147-PU 893-GN-18 135-BU-14 21 210-BK
200-BK -18 892-BR-18 210-BK -14
200-BK -18 152-BU C569-Y L-14
201-BK -18 229-BK -14
200-BK L973-GN
235-BK -18 235-BK -18
607-PK -18
607-PK -18
200-BK -10 200-BK -10 A 537-P K-18
323-WH-10 168-RD-10 123-WH-18
200-BK -18
200-BK -18
607-PK -18
325-PK -18 2 325-PK -18 1 325-PK -18 607-PK -18 200-BK -14
365-YL-18 1 2 578-BU 200-BK
535-BU-18 200-BK
200-BK -18
L8 L8
200-BK -18 200-BK
200-BK -18 200-BK
L6 L6
200-BK -18
200-BK
200-BK -14
168-RD-18 1 200-BK -14
L976-GN-18 2 607-PK -18 200-BK
535-BU-18
575-YL-18 143-BR-18 1
576-PK -18 M743-GN-18 2
200-BK -18
200-BK -18 150-OR-18 1
L10
168-RD-18 780-PU-18 2
M736-B U-18
365-YL-18 169-PK -18 K 906-GN-18 1
L976-GN-18 K 907-B U-18 A 768-B U-18 2
A 770-P K-18 A 769-GY-18 3
L7
L976-GN-18 L969-WH-18 105-RD 4
L976-GN-18 235-BK -18 A 537-P K-18 5
L968-OR-18 K 907-B U-18 6
C538-O R-18 F774-WH-18 326-RD 7
200-BK -18 C537-G N-18 F773-OR-18 L969-WH-18 8
K 906-GN-18 L968-OR-18 9
365-YL-18 A 768-B U-18 308-YL 10
L976-GN-18 L. CHAS SI S 1 646-RD-18 235-BK -18 A 770-P K-18 11
L. BO OM 2 645-RD-18 A 769-GY-18 307-OR 12
329-YL-18 3 150-OR-18
W. INT (6) 4 A 586-OR-18 780-PU-18 A 755-P K-18 1
W. INT (3) 5 590-GY-18 308-YL A 756-B U-18 2
TRAV EL MODE SW 6 M734-B R-18 326-RD A 757-GY-18 3
A EC M ODE SW 7 M742-P U-18 307-OR A 758-B R-18 4
A LA RM CANCEL SW 8 M741-GY-18 105-RD L972-BU-18 5
329-YL-18 +B 9 113-OR-18 A 755-P K-18 F774-WH-18 6
168-RD-18 TRAV EL MODE IND 1 10 H467-WH-18 A 756-B U-18 F773-OR-18 7
TRAV EL MODE IND 2 11 A 757-GY-18 607-PK 8
168-RD-18 12 A 758-B R-18 M736-B U-18 9
168-RD-18 13 235-BK -18 169-PK -18 10
168-RD-10 W. LOW 14 501-GN-18 200-BK -18 200-BK -18 11
323-WH-10 15 607-PK 235-BK -18 12
16 M743-GN-18
WAS H 17 530-OR-18 143-BR-18 235-BK -18
A LA RM CANCEL IND 18 H465-G N-18 L972-BU-18 235-BK -18
A EC M ODE IND 19 H466-B U-18 E 472-GN-18 235-BK -18
GND 20 200-BK -18 E 473-GY-18 235-BK -18
K 843-GN-18 235-BK -18
K 847-P U-18 200-BK -18
W. CCW 1 A 579-OR 235-BK -18 200-BK -18
W. CW 2 A 580-B R 235-BK -18 200-BK -18
WIP E R CUT 3 A 584-B U-18 235-BK -18
INT (6) 4 A 586-OR-18 235-BK -18 E 472-GN-18 1
WA+ 5 506-PU-18 235-BK -18 E 473-GY-18 2
A CC 6 118-GY 200-BK -18 K 843-GN-18 3
WAS H 7 530-OR-18 A 537-P K-18 K 847-P U-18 4
LOW 8 501-GN-18
INT (3) 9 590-GY-18
GND 10 200-BK
RIS E. S 11
S TOP 12 A 582-P U
REV 13 A 581-GN
1 410-WH-18
2 235-BK -18
403-GN-18
200-BK -18
129-BU
200-BK

Manual Maintenance Interval Schedule Caterpillar 320d R L Hydraulic Excavators

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Manual Maintenance Interval Schedule Caterpillar 320d R L Hydraulic Excavators

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7%*)8='%8'31

320D RR and 320D LRR

i02517979 Fuel System - Prime ........................................... 160

Initial 500 Hours (for New Systems, Refilled

Every 500 Service Hours

Every 500 Service Hours or 3 Months

Every 600 Service Hours of Continuous

Every 1000 Service Hours or 6 Months

Every 2000 Service Hours or 1 Year

Every 3 Years After Date of Installation or

Every 6000 Service Hours or 3 Years

Air Conditioner/Cab Heater Battery - Recycle

Battery Hold-Down - Tighten

Tighten the hold-downs for the battery in order to

Battery or Battery Cable -

1. Slide the operator seat forward.

8. Connect the positive battery cable of the battery.

9. Connect the negative battery cable of the battery.

10. Install the key and turn the battery disconnect

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

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

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

Apply lubricant through all fittings after operation

Wipe all fittings before you apply lubricant.

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

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

5. Check the deflection again.

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

6. Close the engine hood.

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

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

Two shims of different thickness are used at location

Bucket Linkage - Lubricate

Note: Caterpillar recommends the use of 5%

Wipe all fittings before you apply lubricant.

1. Position the machine on a level surface and lower

2. Slowly operate the swing control lever until stick

3. Place the hydraulic lockout control in the LOCKED

2. Secure the bucket to the stick.

3. Remove plug (8).

4. Apply grease through fitting (5).

5. Fill until grease flows out of plug (8).

6. Install plug (8) and tighten plug (8).

7. Continue to fill with grease until the grease is

8. Apply lubricant through fittings for the bucket

Personal injury or death can result from bucket

Block the bucket before changing bucket tips or

Bucket Tips g01053737

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

1. The retainer can be removed from the top of the g01053732

 Use a hammer and a punch in order to drive out

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

3. The retainer can be installed from the top of the

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

Note: Some side cutters may be rotated for additional

Bucket Tips - Inspect/Replace

Block the bucket before changing the bucket

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

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

b. Align extractor (5) with the pin.

c. Strike the Pin-Master at the back of the tool

Note: Discard the old pin and the retainer assembly.

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

7%*)8='%8'31

Use a hammer and a punch in order to drive out

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

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

Air Inlet Heater Circuit (2) This circuit breaker is

Operation and Maintenance Manual,

Keep the lids on empty sampling bottles until you

Place the sample in the mailing tube immediately

Never collect samples from expansion bottles.

Restricted Air Filter indicator on the monitor

Exhaust smoke is still black after the installation

2. See Operation and Maintenance Manual, Engine