Cat 17 Pelle Maintenance

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  • 2010 CaterpillarAll Rights Reserved

    MAINTENANCE INTERVALSOperation and Maintenance Manual Excerpt

  • SEBU7218October 1998

    Operation andMaintenanceManual317B L and 317B LN Excavator9WW1-Up (Machine)6DZ1-Up (Machine)5HK1-Up (3046 Engine)

  • 136Maintenance SectionMaintenance Interval Schedule

    i00998887

    Maintenance Interval ScheduleSMCS Code: 7000

    Note: All safety information, warnings, andinstructions must be read and understood beforeyou perform any operation or any maintenanceprocedure.

    Before each consecutive interval is performed, allof the maintenance requirements from the previousinterval must also be performed.

    When Required

    Air Conditioner/Cab Heater Filter - Inspect/Replace ............................................................. 138Battery - Recycle ................................................ 138Battery, Battery Cable or Battery Disconnect Switch -Replace ............................................................. 140Boom Base Pins - Lubricate ............................... 141Bucket Linkage - Inspect/Adjust ......................... 145Bucket Tips - Inspect/Replace ............................ 146Cab Air Filter - Clean/Replace ............................ 147Circuit Breakers - Reset ...................................... 148Engine Air Filter Primary Element -Clean/Replace .................................................. 158Engine Air Filter Secondary Element - Replace .. 159Engine Air Filter Service Indicator - Inspect ........ 160Ether Starting Aid Cylinder - Replace ................. 163Fuses - Replace .................................................. 170In-Line Refrigerant Dryer - Check/Replace ......... 183Oil Filter - Inspect ................................................ 185Refueling Pump Strainer - Clean ........................ 186Track Adjustment - Adjust ................................... 192Windshield Washer Reservoir - Fill ..................... 200Windshield Wipers - Inspect/Replace ................. 200

    Every 10 Service Hours or Daily for First 100Hours

    Boom, Stick and Bucket Linkage - Lubricate ...... 141

    Every 10 Service Hours or Daily

    Cooling System Level - Check ............................ 156Engine Oil Level - Check .................................... 161Fuel System Water Separator - Drain ................. 168Fuel Tank Water and Sediment - Drain ............... 170Hydraulic System Oil Level - Check ................... 177Indicators and Gauges - Test .............................. 184Radiator Core - Clean ......................................... 186Seat Belt - Inspect .............................................. 187Track Adjustment - Inspect ................................. 194Travel Alarm - Test .............................................. 194Undercarriage - Check ........................................ 195Walk-Around Inspection ...................................... 198Windows - Clean ................................................. 199

    Every 10 Service Hours or Daily for MachinesUsed in Severe Applications

    Boom, Stick and Bucket Linkage - Lubricate ...... 141Boom, Stick and Bucket Linkage - Lubricate ...... 143

    Every 50 Service Hours or Weekly

    Boom, Stick and Bucket Linkage - Lubricate ...... 141Boom, Stick and Bucket Linkage - Lubricate ...... 143Quick Coupler - Lubricate ................................... 185

    Initial 100 Service Hours

    Fuel System Filter - Replace .............................. 166Fuel System Priming Pump - Operate ................ 167

    Every 100 Service Hours

    Battery Electrolyte Level for Conventional Battery -Check ................................................................ 139

    Initial 250 Service Hours

    Engine Valve Lash - Check ................................. 162Final Drive Oil - Change ..................................... 164Hydraulic System Oil Filter - Replace ................. 175Hydraulic System Oil Return Filter - Replace ..... 178Swing Drive Oil - Change ................................... 188

    Every 250 Service Hours

    Battery Electrolyte Level for Low MaintenanceBattery - Check ................................................. 139

    Every 250 Service Hours or Monthly

    Condenser (Refrigerant) - Clean ........................ 148Cooling System Coolant Additive (DEAC) - Add .. 153Cooling System Hoses - Inspect ......................... 155Engine Oil Sample - Obtain ................................ 162Final Drive Oil Level - Check .............................. 165Final Drive Oil Sample - Obtain .......................... 165Hydraulic System Oil Sample - Obtain ............... 182Swing Bearing - Lubricate ................................... 188Swing Drive Oil Level - Check ............................ 189Swing Drive Oil Sample - Obtain ........................ 190V-Belts - Inspect/Adjust/Replace ........................ 196

    Every 500 Service Hours

    In-Line Refrigerant Dryer - Check/Replace ......... 183

    Every 500 Service Hours or 3 Months

    Fuel System Filter - Replace .............................. 166Fuel System Priming Pump - Operate ................ 167Fuel System Priming Pump Strainer - Clean ...... 168Fuel Tank Cap and Strainer - Clean ................... 169Hydraulic System Oil Filter - Replace ................. 175

  • 137Maintenance Section

    Maintenance Interval Schedule

    Every 1000 Service Hours

    Battery Hold-Down - Tighten ............................... 140

    Every 1000 Service Hours or 6 Months

    Hydraulic System Oil Return Filter - Replace ..... 178Swing Drive Oil - Change ................................... 188Water Pump Bearing - Lubricate ......................... 199

    Every 2000 Service Hours or Yearly

    Engine Valve Lash - Check ................................. 162Final Drive Oil - Change ..................................... 164Hydraulic System Oil - Change ........................... 172In-Line Refrigerant Dryer - Check/Replace ......... 183Swing Gear - Lubricate ....................................... 191

    Every 3000 Service Hours or 2 Years

    Cooling System Coolant (DEAC) - Change ........ 149

    Every 3000 Service Hours or 3 Years

    Cooling System Coolant Extender (ELC) - Add .. 154

    Every 3 Years

    Seat Belt - Replace ............................................. 187

    Every 6000 Service Hours or 6 Years

    Cooling System Coolant (ELC) - Change ........... 151

  • 138Maintenance SectionAir Conditioner/Cab Heater Filter - Inspect/Replace

    i00546232

    Air Conditioner/Cab HeaterFilter - Inspect/ReplaceSMCS Code: 7309-040; 7309-510

    NOTICEAn air filter element plugged with dust will result in de-creased performance and service life to the air condi-tioner or cab heater (if equipped).

    To prevent decreased performance, clean the air filterelement, as required.

    g00275522Illustration 108

    The air conditioner filter is on the lower left side ofthe cab.

    1. Slide the operator seat forward.

    2. Loosen the bolts and remove the cover.

    3. Slide the filter element outward.

    4. Clean the filter element with a maximum of200 kPa (30 psi) pressure air.

    5. After you clean the filter element, inspect the filterelement. If the filter element is damaged or badlycontaminated, use a new filter element. Make surethat the filter element is dry.

    6. Install the filter element and the cover.

    i00059329

    Battery - RecycleSMCS Code: 1401-561

    Always recycle a battery. Never discard a battery.

    Always return used batteries to one of the followinglocations:

    A battery supplier

    An authorized battery collection facility

    Recycling facility

  • 139Maintenance Section

    Battery Electrolyte Level for Conventional Battery - Check

    i00930551

    Battery Electrolyte Level forConventional Battery - CheckSMCS Code: 1401-535-FLV

    Each battery cell should not require more than 30 cc(1 oz) of water weekly. This usage of water is typicalwith the proper charging rate and with a moderateclimate.

    When you are operating the machine in extremetemperatures, check the water in the battery cellsweekly.

    1. Inspect the electrolyte level in each battery cell.Maintain the electrolyte level to the bottom of thefiller openings. Use distilled water. If distilled wateris not available, use clean drinking water.

    i00930639

    Battery Electrolyte Level forLow Maintenance Battery -CheckSMCS Code: 1401-535-FLV

    Each battery cell should not require more than 30 cc(1 oz) of water weekly. This usage of water is typicalwith the proper charging rate and with a moderateclimate.

    When you are operating the machine in extremetemperatures, check the water in the battery cellsweekly.

    1. Inspect the electrolyte level in each battery cell.Maintain the electrolyte level to the bottom of thefiller openings. Use distilled water. If distilled wateris not available, use clean drinking water.

  • 140Maintenance SectionBattery Hold-Down - Tighten

    i00934872

    Battery Hold-Down - TightenSMCS Code: 7257

    Tighten the hold-downs for the battery in order toprevent the batteries from moving during machineoperation.

    i00124321

    Battery, Battery Cable orBattery Disconnect Switch -ReplaceSMCS Code: 1401-510; 1402-510; 1402-510

    1. Turn the engine start switch key to the OFFposition. Turn all of the switches to the OFFposition.

    2. Turn the battery disconnect switch to the OFFposition. Remove the disconnect switch key.

    3. Disconnect the battery cable at the batterydisconnect switch. The battery disconnect switchis connected to the machine frame.

    Note: Do not allow the disconnected battery cable tocontact the battery disconnect switch.

    4. Disconnect the negative battery cable at thebattery that is connected to the battery disconnectswitch. If the machine has four 12 volt batteries,disconnect the negative battery cables of two ofthe batteries.

    5. Make any necessary repairs or replace the battery.

    6. Reconnect the negative battery cable at thebattery that is connected to the battery disconnectswitch.

    7. Reconnect the battery cable at the batterydisconnect switch.

    8. Install the disconnect switch key and turn thebattery disconnect switch to the ON position.

  • 141Maintenance Section

    Boom Base Pins - Lubricate

    i00821394

    Boom Base Pins - LubricateSMCS Code: 6501-086

    When the boom pin is replaced, lubricate the newboom pin.

    g00101281Illustration 109

    1. Park the machine on a level surface and lowerthe bucket to the ground.

    g00103842Illustration 110

    2. Vent plug (1) and fitting (2) are on the base ofthe boom. Remove vent plug (1). Apply lubricantthrough fitting (2) until lubricant comes out of theplug hole.

    3. Install vent plug (1).

    i00890453

    Boom, Stick and BucketLinkage - Lubricate(VA Boom (If Equipped))SMCS Code: 6501-086; 6502-086; 6513-086

    Service a new machine after Every 10 Service Hoursonly within the initial 100 service hours.

    After the initial 100 service hours of operation, servicethe boom, the stick, and the bucket linkage afterEvery 50 Service Hours.

    Note: If the machine is operated under severeconditions that might cause abrasive material to enterthe cylinder bearings or if the hydraulic hammer isused, service the boom, the stick, and the bucketlinkage after Every 10 Service Hours.

    g00393802Illustration 111

    1. Wipe all fittings before you apply lubricant.

    g00287575Illustration 112

    2. Apply lubricant through the fitting at the base ofeach boom cylinder.

  • 142Maintenance SectionBoom, Stick and Bucket Linkage - Lubricate

    g00293318Illustration 113

    3. Fittings (1), (2), (3), (4) and (5) are located at thebase of the boom. To lubricate the boom cylinderrod, apply lubricant through fitting (1) and (2). Tolubricate the head end of the boom angle cylinder,apply lubricant through fitting (3). To lubricatethe lower boom bearings, apply lubricant throughfitting (4) and (5).

    Use Steps 3.a through 3.d to ensure properlubrication of the lower boom bearings and of theboom cylinder rod end bearings.

    a. Apply lubricant through the fitting while theboom is raised and all of the implement issuspended.

    b. Lower the boom and the implement to theground.

    c. Apply a slight downward pressure on theimplement.

    d. Apply lubricant through the fitting.

    g00293320Illustration 114

    4. Fittings (6), (7), and (8) are located near theconnection point of the boom and of the stick. Tolubricate the head end of the stick cylinder, applylubricant through fitting (6). To lubricate the pivotpoint of the VA boom, apply lubricant throughfitting (7). To lubricate the rod end of the boomangle cylinder, apply lubricant through fitting (8).

    g00293375Illustration 115

    5. Apply lubricant through fittings (9) and (10). Thesefittings are located on the link.

    6. Apply lubricant through fitting (11). This fitting islocated on the rod end of the bucket cylinder.

    7. Apply lubricant through fitting (12). This fitting islocated on the stick.

    8. Apply lubricant through fittings (13) and (14).These fittings are located on the power link.

    g00293479Illustration 116

  • 143Maintenance Section

    Boom, Stick and Bucket Linkage - Lubricate

    g00293376Illustration 117

    9. Apply lubricant through fittings (15). These fittingsare located at the junction of the boom and thestick.

    10.Apply lubricant through fitting (16). This fitting islocated on the rod end of the stick cylinder.

    11.Apply lubricant through fitting (17). This fitting islocated on the head end of the bucket cylinder.

    i00890422

    Boom, Stick and BucketLinkage - LubricateSMCS Code: 6501-086; 6502-086; 6513-086

    Service a new machine after Every 10 Service Hoursonly within the initial 100 service hours.

    After the initial 100 service hours of operation, servicethe boom, the stick, and the bucket linkage afterEvery 50 Service Hours.

    Note: If the machine is operated under severeconditions that might cause abrasive material to enterthe cylinder bearings or if the hydraulic hammer isused, service the boom, the stick, and the bucketlinkage after Every 10 Service Hours.

    g00102057Illustration 118

    1. Wipe all fittings before you apply lubricant.

    g00287575Illustration 119

    2. Apply lubricant through the fitting at the base ofeach boom cylinder.

  • 144Maintenance SectionBoom, Stick and Bucket Linkage - Lubricate

    g00103848Illustration 120

    3. Fittings (1), (2), (3), (4) and (5) are located at thebase of the boom. To lubricate the lower boombearings, apply lubricant through fittings (1) and(2). To lubricate the boom cylinder rod, applylubricant through fittings (3) and (4). To lubricatethe head end of the stick cylinder, apply lubricantthrough fitting (5).

    Use Steps 3.a through 3.d to ensure properlubrication of the lower boom bearings and of theboom cylinder rod end bearings.

    a. Apply lubricant through the fitting while theboom is raised and all of the implement issuspended.

    b. Lower the implement to the ground.

    c. Apply a slight downward pressure on theimplement.

    d. Apply lubricant through the fitting.

    g00103850Illustration 121

    4. Apply lubricant through fittings (6) and (7). Thesefittings are located on the link.

    5. Apply lubricant through fitting (8). This fitting islocated on the rod end of the bucket cylinder.

    6. Apply lubricant through fitting (9). This fitting islocated on the stick.

    7. Apply lubricant through fittings (10) and (11).These fittings are located on the power link.

    g00103854Illustration 122

    g00293477Illustration 123

    8. Apply lubricant through fittings (12). These fittingsare located at the junction of the boom and thestick.

    9. Apply lubricant through fitting (13). This fitting islocated on the rod end of the stick cylinder.

    10.Apply lubricant through fitting (14). This fitting islocated on the head end of the bucket cylinder.

  • 145Maintenance Section

    Bucket Linkage - Inspect/Adjust

    i00142555

    Bucket Linkage -Inspect/AdjustSMCS Code: 6513-025; 6513-040

    When performing this adjustment, put the hy-draulic activation control lever in the LOCKEDposition and stop the engine.

    NOTICEImproperly adjusted bucket clearance could causegalling on the contact surfaces of the bucket andstick, resulting in excessive noise and/or damagedO-ring seals.

    g00101687Illustration 124(1) No gap. (2) Stick boss. (3) Bucket clearance. (4) Shims. (5)Pin. (6) Plate. (7) Bolts. (8) Washers. (9) Location. (10) Flange.(11) Bucket boss.

    The clearance of the bucket linkage on this machinecan be adjusted by shimming. If the gap betweenthe bucket and the stick becomes excessive, adjustbucket 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).

    g00102146Illustration 125Area for linkage adjustment

    1. Position the machine on a level surface and lowerthe bucket to the ground.

    2. Slowly operate the swing control lever until stickboss (2) and the bucket boss (11) are in full facecontact at no gap (1). This will help to determinethe total clearance of the connection point of thestick and of the bucket.

    3. Place the hydraulic activation control lever in theLOCKED position and stop the engine.

    4. Measure bucket clearance (3), which is theexisting total clearance.

    5. Determine the number of shims that need to beremoved from shims (4) by using the followingcalculation:

    Subtract 0.5 mm (0.02 inch ) or 1.0 mm (0.04 inch)from bucket clearance (3).

    6. Remove the appropriate number of shims atlocation (9) in order to meet the above thickness.Make sure that you use a minimum of three0.5 mm (.02 inch) shims. To remove the shims,remove bolts (7), washers (8), and plate (6).

    7. After the correct number of shims has beenremoved and pin (5) is aligned with the pinhole, install plate (6), washers (8), and bolts (7).Tighten bolts (7) to a torque of 460 60 Nm(340 44 lb ft).

    8. After installation, make sure that bucket clearance(3) is still correct.

  • 146Maintenance SectionBucket Tips - Inspect/Replace

    i00641604

    Bucket Tips - Inspect/ReplaceSMCS Code: 6805-040; 6805-510

    Personal injury or death can result from bucketfalling.

    Block the bucket before changing bucket tips orside cutters.

    Bucket Tips

    g00101352Illustration 126(1) This tip is usable. (2) This tip should be replaced. (3) This tiphas been overworn.

    Check the bucket tips for wear. If the bucket tip has ahole, replace the bucket tip.

    g00101354Illustration 127

    1. Drive the pin out of the bucket tip from the retainerside of the bucket tip. Remove the bucket tip andthe retainer.

    g00101355Illustration 128

    2. Clean the adapter and the pin.

    3. Fit retainer (1) into retainer washer (2). Installthis assembly into the groove that is in the sideof adapter (3).

    g00101359Illustration 129

    4. Install the new bucket tip or the rotated bucket tiponto the adapter. To allow greater penetration orless penetration, the bucket tip may be rotated by180 degrees.

    5. From the other side of the retainer, drive the pinthrough the bucket tip, through the adapter, andthrough the retainer.

    6. After you drive the pin, make sure that the retainerfits snugly into the pin groove.

  • 147Maintenance Section

    Cab Air Filter - Clean/Replace

    Side Cutters

    g00287634Illustration 130

    1. Remove the mounting bolts and the side cutters.

    2. Clean the mounting surfaces.

    Note: Some side cutters may be rotated for additionalwear.

    3. Install the new side cutters or the rotated sidecutters.

    i00061455

    Cab Air Filter - Clean/ReplaceSMCS Code: 7342-070; 7342-510

    g00102781Illustration 131

    The cab air filter is behind the cab.

    1. Loosen two bolts (1) and remove filter cover (2)and air filter (3).

    2. Clean the air filter with a maximum of 200 kPa(30 psi) pressure air.

    3. After you clean the air filter, inspect the air filter.If the air filter is damaged or badly contaminated,use a new air filter.

    4. Install the air filter and the filter cover.

    Note: Make sure that the arrow on top of the air filteris facing forward.

  • 148Maintenance SectionCircuit Breakers - Reset

    i00771459

    Circuit Breakers - ResetSMCS Code: 1420-529

    g00353592Illustration 132

    The circuit breakers are inside the access door on the left of themachine.

    Circuit Breaker Reset Push in the buttonin order to reset the circuit breaker. If theelectrical system is working properly, the

    button will remain depressed. If the button does notremain depressed, check the appropriate electricalcircuit. Repair the electrical circuit, if necessary.

    (1) Alternator circuit (60 amp) Thiscircuit breaker is designed to protect thealternator. If the batteries are installed with

    reverse polarity, the circuit breaker would prevent thealternator from damaging the rectifier.

    (4) Battery circuit (30 amp) This circuitbreaker is designed to protect the wiresbetween the batteries and the fuses. If the

    wires are shorted to the machines body, the circuitbreaker would minimize the damage to the wires.

    (2) and (3) Accessory circuits (30 amp) These circuit breakers are designed toprotect the wires between the batteries and

    the fuses.

    i00730834

    Condenser (Refrigerant) -Clean(If Equipped)SMCS Code: 1805-070

    NOTICEIf excessively dirty, clean condenser with a brush. Toprevent damage or bending of the fins, do not use astiff brush.

    Repair the fins if found defective.

    g00393008Illustration 133

    1. Open the access door on the left side of themachine.

    g00378129Illustration 134

    2. Inspect the condenser for debris. Clean thecondenser, if necessary.

    3. Use clean water to wash off all dust and dirt fromthe condenser.

    4. Close the access door.

  • 149Maintenance Section

    Cooling System Coolant (DEAC) - Change

    i00826740

    Cooling System Coolant(DEAC) - ChangeSMCS Code: 1350-044; 1352-544

    NOTICEDo not change the coolant until you read and under-stand the material found in the Operation and Mainte-nance Manual, Cooling System Specifications sec-tion. Failure to do so could result in damage to thecooling systems components.

    Note: This machine was filled at the factory withCaterpillar Extended Life Coolant. The followinginformation pertains to machines which havebeen subsequently filled with Caterpillar DieselEngine Antifreeze/Coolant (DEAC) or a commercialequivalent.

    If the coolant is dirty or if there is any foaming inthe cooling system, drain the coolant before therecommended interval.

    g00359072Illustration 135

    1. Unlatch the engine hood and raise the enginehood.

    g00288136Illustration 136

    2. Slowly loosen the cooling system pressure capin order to relieve system pressure. Remove thepressure cap.

    g00393008Illustration 137

    3. Open the access door on the left side of themachine.

    g00288138Illustration 138

    Note: Refer to Operation and Maintenance Manual,General Hazard Information for information thatpertains to containing fluid spillage.

    4. Open the drain valve that is under the radiator.Allow the coolant to drain into a suitable container.

    Note: Dispose of drained fluids according to localregulations.

    5. Close the drain valve.

    6. Fill the cooling system with a solution whichconsists of clean water and cooling systemcleaner. The concentration of the cooling systemcleaner should be 6 to 10 percent.

    7. Start the engine. Operate the engine withoutthe cooling system pressure cap until the watertemperature regulator opens and the coolingsystem level stabilizes.

  • 150Maintenance SectionCooling System Coolant (DEAC) - Change

    8. Maintain the cooling system level within 13 mm(.5 inches) of the bottom of the filler pipe.

    9. Install the cooling system pressure cap.

    10.Operate the engine for 90 minutes.

    11.Stop the engine.

    Pressurized System: Hot coolant can cause seri-ous burn. To open cap, stop engine, wait until ra-diator is cool. Then loosen cap slowly to relievethe pressure.

    12.Slowly loosen the cooling system pressure capin order to relieve system pressure. Remove thepressure cap.

    13.Drain the cleaning solution into a suitablecontainer.

    14. Flush the cooling system with water until thedraining water is transparent.

    15.Close the drain valve.

    16.Add the appropriate coolant solution to thecooling system. Refer to the following topics:

    Operation and Maintenance Manual, CoolingSystem Specifications

    Operation and Maintenance Manual, RefillCapacities

    Note: If you are using Caterpillar antifreeze, donot add the supplemental coolant additive at thistime. Also, do not replace the supplemental coolantadditive element at this time.

    17.Start the engine. Operate the engine withoutthe cooling system pressure cap until the watertemperature regulator opens and the coolant levelstabilizes.

    18.Maintain the coolant level within 13 mm (.5 inches)of the bottom of the filler pipe.

    19. Inspect the gasket of the cooling system pressurecap. If the gasket is damaged, replace thepressure cap.

    20. Install the cooling system pressure cap.

    21.Stop the engine.

    g00455603Illustration 139(A) FULL level(B) LOW level

    22.Check the coolant level of the coolant reservoir.Maintain the coolant level between the FULLmark and the LOW mark.

    23. If additional coolant is necessary, remove thereservoir cap and add the appropriate coolantsolution.

    24. Install the reservoir cap.

    25.Close the engine hood and latch the engine hood.

    26.Close the access door on the left side of themachine.

  • 151Maintenance Section

    Cooling System Coolant (ELC) - Change

    i00826749

    Cooling System Coolant (ELC)- ChangeSMCS Code: 1350-044

    NOTICEDo not change the coolant until you read and under-stand the material found in the Operation and Mainte-nance Manual, Cooling System Specifications sec-tion. Failure to do so could result in damage to thecooling systems components.

    NOTICEMixing ELC with other products reduces the effec-tiveness of the coolant and shortens coolant life.Use only Caterpillar products or commercial productsthat have passed the Caterpillar EC-1 specificationsfor pre-mixed or concentrate coolants. Use onlyCaterpillar Extender with Caterpillar ELC. Failure tofollow these recommendations could result in thedamage to cooling systems components.

    If ELC cooling system contamination occurs see thetopic ELC Cooling System Contamination of this op-eration and maintenance manual.

    If the coolant in the machine is changed to ExtendedLife Coolant from another type of coolant, seeOperation and Maintenance Manual, Extended LifeCoolant Cooling System Maintenance.

    g00359072Illustration 140

    1. Unlatch the engine hood and raise the enginehood.

    g00393008Illustration 141

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

    g00288136Illustration 142

    3. Slowly loosen the cooling system pressure capin order to relieve system pressure. Remove thepressure cap.

    g00288138Illustration 143

    Note: Refer to Operation and Maintenance Manual,General Hazard Information for information thatpertains to containing fluid spillage.

    4. Open the drain valve that is located under theradiator. Allow the coolant to drain into a suitablecontainer.

  • 152Maintenance SectionCooling System Coolant (ELC) - Change

    Note: Dispose of drained fluids according to localregulations.

    5. Flush the cooling system with clean water until thedraining water is transparent.

    6. Close the drain valve.

    7. Add the Extended Life Coolant. Refer to thefollowing topics:

    Operation and Maintenance Manual, CoolingSystem Specifications

    Operation and Maintenance Manual, RefillCapacities

    8. Start the engine. Operate the engine withoutthe cooling system pressure cap until the watertemperature regulator opens and the coolant levelstabilizes.

    9. Maintain the coolant level within 13 mm (.5 inches)of the bottom of the filler pipe.

    10. Inspect the gasket of the cooling system pressurecap. If the gasket is damaged, replace thepressure cap.

    11. Install the cooling system pressure cap.

    12.Stop the engine.

    g00455603Illustration 144(A) FULL level(B) LOW level

    13.Check the coolant level of the coolant reservoir.Maintain the coolant level between the FULLmark and the LOW mark.

    14. If additional coolant is necessary, remove thereservoir cap and add the appropriate coolantsolution.

    15. Install the reservoir cap.

    16.Close the engine hood and latch the engine hood.

    17.Close the access door on the left side of themachine.

  • 153Maintenance Section

    Cooling System Coolant Additive (DEAC) - Add

    i00826802

    Cooling System CoolantAdditive (DEAC) - AddSMCS Code: 1352; 1353; 1395

    NOTICEExcessive additive (greater than the recommended6% initial fill) together with concentrations of antifreezegreater than 60% cause deposits to form and can re-sult in radiator tube blockage and overheating.

    Note: This machine was filled at the factory withCaterpillar Extended Life Coolant. The followinginformation pertains to machines which havebeen subsequently filled with Caterpillar DieselEngine Antifreeze/Coolant (DEAC) or a commercialequivalent.

    Check the concentration of the coolant. Use8T-5296 Coolant Conditioner Test Kit to check theconcentration.

    If necessary, add Caterpillar Supplemental CoolantAdditive (SCA).

    Liquid Supplemental CoolantAdditive

    g00359072Illustration 145

    1. Unlatch the engine hood and raise the enginehood.

    g00288136Illustration 146

    2. Slowly loosen the cooling system pressure capin order to relieve system pressure. Remove thepressure cap.

    Note: Refer to Operation and Maintenance Manual,General Hazard Information for information oncontaining fluid spillage.

    3. It may be necessary to drain some coolant fromthe radiator so that Caterpillar SupplementalCoolant Additive can be added to the coolingsystem.

    Note: Dispose of the drained fluids according to localregulations.

    4. Add the Supplemental Coolant Additive to thecooling system. Refer to the following topics forthe proper amount of Caterpillar SupplementalCoolant Additive:

    Operation and Maintenance Manual,Supplemental Coolant Additive (SCA)

    Operation and Maintenance Manual, RefillCapacities

    5. Inspect the gasket of the cooling system pressurecap. If the gasket is damaged, replace thepressure cap.

    6. Install the cooling system pressure cap.

    7. Close the engine hood and latch the engine hood.

  • 154Maintenance SectionCooling System Coolant Extender (ELC) - Add

    i00826754

    Cooling System CoolantExtender (ELC) - AddSMCS Code: 1352; 1353; 1395

    NOTICEMixing Extended Life Coolant (ELC) with other prod-ucts reduces the effectiveness of the coolant andshortens coolant life. Use only Caterpillar productsor commercial products that have passed the Cater-pillar EC-1 specification for premixed or concentratecoolants. Use only Caterpillar Extender with Cater-pillar ELC. Failure to follow these recommendationscould result in the damage to cooling systems com-ponents.

    If ELC cooling system contamination occurs refer toOperation and Maintenance Manual, ELC CoolingSystem Contamination.

    This machine was factory filled with Extended LifeCoolant.

    When a Caterpillar Extended Life Coolant (ELC) isused, an Extender must be added to the coolingsystem. Refer to Operation and Maintenance Manual,Cooling Recommendations for all cooling systemrequirements.

    Check the concentration of the coolant. Use a8T-5296 Coolant Conditioner Test Kit to check theconcentration.

    g00359072Illustration 147

    1. Unlatch the engine hood and raise the enginehood.

    g00393008Illustration 148

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

    g00288136Illustration 149

    3. Slowly loosen the cooling system pressure capin order to relieve system pressure. Remove thepressure cap.

    Note: Refer to Operation and Maintenance Manual,General Hazard Information for information oncontaining fluid spillage.

    4. It may be necessary to drain some coolant fromthe radiator so that Caterpillar Extender can beadded to the cooling system.

    Note: Dispose of the drained fluids according to localregulations.

    5. Add Extender to the cooling system. Refer tothe following topics for the proper amount ofCaterpillar Extender:

    Operation and Maintenance Manual, ExtendedLife Coolant (ELC)

    Operation and Maintenance Manual, RefillCapacities

  • 155Maintenance Section

    Cooling System Hoses - Inspect

    6. Inspect the gasket of the cooling system pressurecap. If the gasket is damaged, replace thepressure cap.

    7. Install the cooling system pressure cap.

    8. Close the engine hood and latch the engine hood.

    9. Close the access door on the left side of themachine.

    i00826806

    Cooling System Hoses -InspectSMCS Code: 1380-040

    g00359072Illustration 150

    1. Unlatch the engine hood and raise the enginehood.

    g00288149Illustration 151

    2. Inspect all hoses for leaks due to cracking andfor softness next to the clamps. Check the hosesfor loose clamps.

    3. Replace hoses that are cracked or soft and tightenany loose clamps.

    Use Steps 3.a through 3.f to replace the hoses.

  • 156Maintenance SectionCooling System Level - Check

    g00288136Illustration 152

    a. Slowly loosen the cooling system pressure capin order to relieve system pressure. Removethe pressure cap.

    Note: Refer to Operation and Maintenance Manual,General Hazard Information for information oncontaining fluid spillage.

    b. Drain the coolant from the cooling system toa level that is below the hose that is beingreplaced.

    Note: Dispose of the drained fluids according to localregulations.

    c. Loosen the hose clamps and disconnect thedamaged hose.

    d. Replace the damaged hose with a new hose.

    e. Replace the hose clamps and tighten the hoseclamps.

    f. Add the appropriate coolant solution to thecooling system. Refer to the Operation andMaintenance Manual, Cooling System Level- Check.

    4. Close the engine hood and latch the engine hood.

    i00826813

    Cooling System Level - CheckSMCS Code: 1350-535

    g00393008Illustration 153

    1. Open the access door on the left side of themachine.

    g00455603Illustration 154(A) FULL Level(B) LOW Level

    2. Check the coolant level of the coolant reservoir.Maintain the coolant level between the FULLmark and the LOW mark.

    If the reservoir is empty, use steps 2.a through 2.i.

  • 157Maintenance Section

    Cooling System Level - Check

    g00359072Illustration 155

    a. Unlatch the engine hood and raise the enginehood.

    g00288136Illustration 156

    b. Slowly loosen the cooling system pressure capin order to relieve system pressure. Removethe pressure cap.

    Note: Refer to Operation and Maintenance Manual,General Hazard Information for information oncontaining fluid spillage.

    c. Add the appropriate coolant solution to thecooling system. Refer to the following topics:

    Operation and Maintenance Manual,Cooling System Specifications

    Operation and Maintenance Manual, RefillCapacities

    d. Start the engine. Operate the engine withoutthe cooling system pressure cap until the watertemperature regulator opens and the coolantlevel stabilizes.

    e. Maintain the coolant level within 13 mm(0.5 inch) of the bottom of the radiator fillerpipe.

    g00102170Illustration 157

    f. Inspect the gasket of the cooling systempressure cap. If the gasket is damaged, replacethe pressure cap.

    g. Install the cooling system pressure cap.

    h. Stop the engine.

    i. Close the engine hood and latch the enginehood.

    Note: Refer to Operation and Maintenance Manual,General Hazard Information for information oncontaining fluid spillage.

    3. If additional coolant is necessary, remove thereservoir cap and add the appropriate coolantsolution.

    4. Install the reservoir cap.

    5. Close the access door on the left side of themachine.

  • 158Maintenance SectionEngine Air Filter Primary Element - Clean/Replace

    i00825226

    Engine Air Filter PrimaryElement - Clean/ReplaceSMCS Code: 1054-070; 1054-510

    g00393008Illustration 158

    1. Open the access door on the left side of themachine.

    g00289172Illustration 159

    2. Loosen the three cover latches and remove theair cleaner cover.

    g00101415Illustration 160

    3. Remove the primary filter element from the aircleaner housing.

    4. Clean the air cleaner cover and the inside of theair cleaner housing.

    5. Inspect the O-ring seal on the air cleaner cover.Replace the O-ring seal if the O-ring seal is wornor damaged.

    NOTICEDo not clean the filter elements by bumping or tappingthem. Do not use filter elements with damaged pleats,gaskets or seals. Engine damage can result.

    Make sure the cleaned filter elements are completelydry before installing into the filter housing. Water re-maining in the elements can cause false indicationsof contamination in Scheduled Oil Sampling test re-sults.

    6. Clean the primary filter. Inspect the primary filter.

    Primary filter elements can be cleaned withpressure air, pressure water or a detergentwashing. When pressure water is used themaximum pressure should not exceed 280 kPa(40 psi).

    Refer to Operation and Maintenance, GeneralHazard Information before you use pressure airin order to clean the primary filter element.

    g00102970Illustration 161

    7. Direct air or water along the pleats inside theprimary filter element and outside the primary filterelement.

    The primary filter element can be washed in warmwater and nonsudsing household detergent. Rinseinside the pleats and outside the pleats. Allow theprimary filter element to air dry fully.

    8. Inspect the primary filter element after cleaning.Do not use a primary filter element with damagedpleats, damaged gaskets or damaged seals.

  • 159Maintenance Section

    Engine Air Filter Secondary Element - Replace

    9. Encase the clean primary filter element and storethe clean primary filter element in a clean, dryplace.

    10. Install the clean primary filter.

    11. Install the air cleaner cover and close the latchessecurely.

    g00288168Illustration 162

    Note: Install the air cleaner cover properly. The valvemust point downward.

    12.Change the filter if any of the following conditionsoccurs:

    Restricted Air Filter indicator on the monitorpanel still comes on.

    Exhaust smoke is still black after the installationof a primary filter.

    Note: The primary filter can be cleaned up to sixtimes. Replace the primary filter if the primary filterhas been in service for one year.

    13.Close the access doors.

    i00702568

    Engine Air Filter SecondaryElement - ReplaceSMCS Code: 1054-510

    NOTICEAlways replace the secondary filter element. Never at-tempt to reuse the secondary filter element by clean-ing the element.

    When the primary filter element is replaced, the sec-ondary filter element should be replaced.

    The secondary filter element should also be replacedif the restricted Air Filter indicator comes on after theinstallation of a clean primary filter element or if theexhaust smoke is still black.

    g00101721Illustration 163

    1. Open the access door on the front left side of themachine.

    2. See Operation and Maintenance Manual, EngineAir Filter Primary Element - Clean/Replace.Remove the air cleaner cover from the air cleanerhousing. Remove the primary filter element fromthe air cleaner housing.

    g00101451Illustration 164

  • 160Maintenance SectionEngine Air Filter Service Indicator - Inspect

    3. Remove the secondary filter element.

    4. Cover the air inlet opening. Clean the inside ofthe air cleaner housing.

    5. Remove the cover from the air inlet opening.

    6. Install the new secondary filter element.

    7. Install the primary filter element.

    8. Install the air cleaner cover and close the latchessecurely.

    9. Close the access door.

    i00091440

    Engine Air Filter ServiceIndicator - InspectSMCS Code: 7452-040-DJ

    NOTICEService the air cleaner only when the engine stopped.Engine damage could result.

    g00101403Illustration 165

    Check the air filter indicator while the engine isrunning under a full load. Service the air cleaner ifthe restricted air filter indicator on the monitor panelcomes on. Stop the engine before you service theair cleaner.

  • 161Maintenance Section

    Engine Oil Level - Check

    i00902996

    Engine Oil Level - CheckSMCS Code: 1000-535

    NOTICEDo not overfill the crankcase. Engine damage can re-sult.

    Note: This machine is equipped with a function forchecking fluid levels. However, if the machine ison an incline or the engine has been stopped onlyfor a short time, the engine oil does not return tothe crankcase. The fluid level cannot be properlychecked. Park the machine on level ground andcheck the oil level after the engine has been stoppedfor at least 30 minutes.

    Check the oil level while the engine is stopped. Donot check the oil level while the engine is running.

    g00359072Illustration 166

    1. Unlatch the engine hood and raise the enginehood.

    g00288174Illustration 167

    2. Remove the dipstick. Wipe the oil off the dipstickand reinsert the dipstick.

    g00104116Illustration 168

    3. Remove the dipstick and check the dipstick. Theoil level should be between the H mark and theL mark.

    NOTICEOperating your engine when the oil level is above theH mark could cause the crankshaft to dip into the oil.This could lead to excessively high oil temperatureswhich can reduce the lubricating characteristics of theoil, lead to bearing damage, and could result in loss ofengine power.

    g00288179Illustration 169

    Note: Refer to Operation and Maintenance Manual,General Hazard Information for information onContaining Fluid Spillage.

    4. Remove the oil filler plug in order to add oil, ifnecessary. See Operation and MaintenanceManual, Refill Capacities.

    Note: If the oil is deteriorated or badly contaminated,change the oil regardless of the maintenance interval.

    5. Clean the oil filler plug. Install the oil filler plug.

    6. Close the engine hood. Latch the engine hood.

  • 162Maintenance SectionEngine Oil Sample - Obtain

    i00857468

    Engine Oil Sample - ObtainSMCS Code: 1000-008; 7542-008

    Refer to Operation and Maintenance Manual, SOSOil Analysis for information that pertains to obtaininga sample of the engine oil.

    Obtain a sample of the engine oil through the dipstickopening.

    i00074962

    Engine Valve Lash - CheckSMCS Code: 1105-535

    In order to perform the complete procedure for thevalve lash adjustment, refer to the Service Manual.

  • 163Maintenance Section

    Ether Starting Aid Cylinder - Replace

    i00821567

    Ether Starting Aid Cylinder -Replace(If Equipped)SMCS Code: 1456-510-CD

    g00393008Illustration 170

    1. Open the access door on the left side of themachine.

    g00101321Illustration 171

    2. Loosen the cylinder retaining clamp. Unscrew theempty ether starting aid cylinder and remove theempty ether starting aid cylinder.

    g00104888Illustration 172

    3. Remove the used gasket. Install the new gasket.A new gasket is provided with each new etherstarting aid cylinder.

    4. Install the new ether starting aid cylinder. Tightenthe ether starting aid cylinder hand tight. Tightenthe cylinder retaining clamp securely.

    5. Close the access door.

  • 164Maintenance SectionFinal Drive Oil - Change

    i00733394

    Final Drive Oil - ChangeSMCS Code: 4050-044-FLV

    g00327323Illustration 173

    1. Position one final drive so that oil drain plug (1) isat the bottom.

    Note: Refer to Operation and Maintenance Manual,General Hazard Information for information onContaining Fluid Spillage.

    2. Remove drain plug (1) and level plug (2). Allowthe oil to drain into a suitable container.

    3. Clean the plugs and inspect the O-ring seals. Ifwear or damage is evident, replace the drain plug,the level plug, and/or the O-ring seals.

    4. Install drain plug (1).

    5. Fill the final drive to the bottom of the opening onlevel plug (2). See Operation and MaintenanceManual, Lubricant Viscosities and Operation andMaintenance Manual, Refill Capacities.

    6. Install level plug (2).

    7. Perform Step 1 to Step 6 on the other final drive.Use a different container for the oil so that the oilsamples from the final drives will be separate.

    8. Completely remove the oil that has spilled ontosurfaces.

    9. Start the engine and allow the final drives to runthrough several cycles.

    10.Stop the engine. Check the oil level.

    11.Check the drained oil for metal chips or forparticles. If there are any chips or particles,consult your Caterpillar dealer.

    12.Properly dispose of the drained material. Obeylocal regulations for the disposal of the material.

  • 165Maintenance Section

    Final Drive Oil Level - Check

    i00733455

    Final Drive Oil Level - CheckSMCS Code: 4050-535-FLV

    g00327323Illustration 174

    1. Position one final drive so that oil drain plug (1) isat the bottom.

    Note: Refer to Operation and Maintenance Manual,General Hazard Information for information onContaining Fluid Spillage.

    2. Remove oil level plug (2).

    3. Check the oil level. The oil should be near thebottom of the level plug opening.

    4. Add oil through the level plug opening, ifnecessary.

    Note: Overfilling the final drive will cause the seals onthe travel motor to allow hydraulic oil or water to enterthe final drive. This may contaminate the final drive.

    5. Clean oil level plug (2). Inspect the O-ring seal.Replace the O-ring seal if the O-ring seal is wornor damaged.

    6. Install oil level plug (2).

    7. Repeat the procedure for the other final drive.

    i00998891

    Final Drive Oil Sample - ObtainSMCS Code: 4050-008

    g00327323Illustration 175(1) Oil drain plug(2) Oil level plug

    1. Position the final drive so that oil drain plug (1) isat the bottom.

    2. Remove oil level plug (2).

    3. Obtain a sample of the final drive oil through thehole for the oil level plug.

    4. Install oil level plug (2).

    Refer to Operation and Maintenance Manual, SOSOil Analysis for more information on obtaining asample of the final drive oil.

  • 166Maintenance SectionFuel System Filter - Replace

    i00825264

    Fuel System Filter - ReplaceSMCS Code: 1261-510

    NOTICETurn the disconnect switch OFF or disconnect the bat-tery when changing fuel filters.

    Do not fill fuel filters with fuel before installing them.Contaminated fuel will cause accelerated wear to fuelsystems parts.

    g00359072Illustration 176

    1. Unlatch the engine hood and raise the enginehood.

    Note: Refer to Operation and Maintenance Manual,General Hazard Information for information onContaining Fluid Spillage.

    g00288334Illustration 177

    2. Remove the filter.

    Note: This fuel filter is a cartridge type filter. This typeof filter cannot be reused.

    Note: Always discard the used filters according tolocal regulations.

    3. Clean the filter mounting base. Make sure that allof the used seal is removed.

    g00102044Illustration 178

    4. Coat the seal of the new filter with clean dieselfuel.

    5. Install the new fuel filter by hand. When the sealcontacts the filter mounting base, tighten the filterby an additional 3/4 turn.

    6. Prime the fuel system. Refer to Operation andMaintenance Manual, Fuel System Priming Pump- Operate.

    7. Close the engine hood and latch the engine hood.

    Releasing Air From Fuel SystemAfter the fuel filter is replaced, release the air fromthe fuel system. Use the following procedure.

    g00288797Illustration 179

    1. Place engine speed dial (1) at the low idle position.

    2. Turn engine start switch (2) to the ON position andallow the engine to crank for ten to fifteen seconds.This will remove the air from the fuel system.

  • 167Maintenance Section

    Fuel System Priming Pump - Operate

    3. When the above procedure has been performed,the engine will be ready to start. If the enginedoes not start, prime the fuel system. For moredetails, refer to the next section of this Operationand Maintenance Manual, Fuel System PrimingPump - Operate.

    4. After this procedure is completed, operate theengine at low idle for several minutes. Check thefuel system for leaks.

    i00645608

    Fuel System Priming Pump -OperateSMCS Code: 1258

    After the strainer is cleaned, fill up the fuel tank andthe fuel system priming pump. Use the followingprocedure. If the engine stalled due to no fuel, top upthe fuel tank and the fuel system priming pump usingthe following procedure.

    g00288425Illustration 180

    1. Loosen air vent (1) on the fuel filter.

    2. Unlock the priming pump by turning plunger (2)counterclockwise. Pull the plunger up. Operatethe priming pump by moving plunger (2) up anddown until fuel that is free of air bubbles flows outof air vent (1).

    3. When the fuel flows free of air bubbles, lock thepriming pump. Push the plunger inward and rotatethe plunger in a clockwise motion. This motion willlock the priming pump.

    4. Tighten air vent (1).

    Note: Lock the priming pump before the vent plug istightened. Pressure in the fuel system could makelocking the plunger in place difficult. Wipe away anyspilled fuel.

    5. After priming the fuel system, run the engineat low idle for several minutes. Check the fuelsystem for leaks.

  • 168Maintenance SectionFuel System Priming Pump Strainer - Clean

    i00645969

    Fuel System Priming PumpStrainer - CleanSMCS Code: 1258

    Clean the strainer whenever a loss of engine poweris still apparent after changing the fuel filter.

    g00288503Illustration 181

    Note: Refer to Operation and Maintenance Manual,General Hazard Information for information onContaining Fluid Spillage.

    1. Disconnect the fuel line at the fuel transfer pump.Use a plug to stop the fuel leakage.

    2. Remove bolt (1).

    3. Remove screen (2) from bolt (1). Wash the screenin a clean, nonflammable solvent.

    4. Install the screen into the bolt.

    5. Install bolt (1). Remove the plug from the fuel lineand reconnect the fuel line to the fuel transferpump.

    i00834261

    Fuel System Water Separator- DrainSMCS Code: 1263

    g00393008Illustration 182

    1. Open the access door on the left side of themachine.

    g00293673Illustration 183

    2. Turn the drain valve that is located at thebottom of the primary filter/water separatorcounterclockwise.

    Note: Refer to Operation and Maintenance Manual,General Hazard Information for information oncontaining fluid spillage.

    3. Drain the water and drain the sediment into asuitable container.

    Note: Dispose of drained fluids according to localregulations.

    4. Close the drain valve.

    5. Close the access door.

  • 169Maintenance Section

    Fuel Tank Cap and Strainer - Clean

    i00075601

    Fuel Tank Cap and Strainer -CleanSMCS Code: 1273-070-STR

    g00104237Illustration 184

    1. Remove the fuel cap and the fuel fill screen.

    g00104238Illustration 185

    2. Inspect the cap. Replace the cap if the cap isdamaged.

    g00104239Illustration 186

    3. Wash the fuel fill screen in a clean, nonflammablesolvent and dry the fuel fill screen.

    4. Install the fuel fill screen.

    5. Put a light coating of fuel oil on the cap gasket.

    6. Install the fuel cap.

  • 170Maintenance SectionFuel Tank Water and Sediment - Drain

    i00645599

    Fuel Tank Water and Sediment- DrainSMCS Code: 1273-543

    g00288395Illustration 187

    Note: Refer to Operation and Maintenance Manual,General Hazard Information for information oncontaining fluid spillage.

    1. Open the drain valve that is located under the fueltank. Allow the water and the sediment to draininto a suitable container.

    Note: Dispose of drained fluids according to localregulations.

    2. Close the drain valve.

    Fill the Fuel TankYou can now add fuel to the fuel tank, if necessary.Remove the fuel tank cap and pump fuel through theopening.

    Make sure that you lock the fuel tank cap after therefueling is complete.

    Certain machines are equipped with electric refuelingpumps. For more information, see Operation andMaintenance Manual, Electric Relueling Pump.

    i00808451

    Fuses - ReplaceSMCS Code: 1417-510

    g00293681Illustration 188

    The fuse panel is located on the left console. Openthe access cover for fuse access.

    Fuses Fuses protect the electricalsystem from damage that is caused byoverloaded circuits. Change a fuse if the

    element separates. If the element of a new fuseseparates, check the circuit and/or repair the circuit.

    NOTICEAlways replace fuses with the same type and capacityfuse that was removed. Otherwise, electrical damagecould result.

    NOTICEIf it is necessary to replace fuses frequently, an elec-trical problem may exist.

    Contact your Caterpillar dealer.

    To replace a fuse, use a puller that is stored in thefuse panel. Four fuses of 10 Amperes are containedin the fuse panel as spare fuses and two fuses of 15Amperes are contained in the fuse panel as sparefuses.

    The following list identifies the circuits that areprotected by each fuse. The amperage for each fuseis included with each circuit.

  • 171Maintenance Section

    Fuses - Replace

    g00383533Illustration 189

    g00383594Illustration 190

    Timer Relay (1) 15 Amp

    Cab Dome Light (2) 5 Amp

    Cab and Chassis Lamp (3) 15 Amp

    Engine Start Switch Key (4) 10 Amp

    Heater and Air Conditioner (If Equipped) (5) 15 Amp

    Horn (6) 5 Amp

    Electric Refueling Pump (If Equipped) (7) 15Amp

    Engine Controller or Pump Controller (8) 10Amp

    Seat Heater (If Equipped) (9) 5 Amp

    Boom Lamp (10) 10 Amp

    Radio (If Equipped) / Switch Panel (11) 5 Amp

    AUTO Lubricator (If Equipped) (12) 10 Amp

    Auxiliary Circuit (13) 10 Amp

    Cigar Lighter (14) 10 Amp

    Hydraulic Lock Limit Switch or Engine Governor(15) 5 Amp

    Hydraulic Solenoid (16) 5 Amp

    Inspection Lamp (If Equipped) (17) 10 Amp

    Lower Windshield Washer and Lower WindshieldWiper (If Equipped) (18) 10 Amp

    Converter (19) 10 Amp

    Auxiliary Circuit (20) 10 Amp

    Windshield Washer and Windshield Wiper (21) 10 Amp

    Backup (22) 5 Amp

    Auxiliary Circuit (23) 10 Amp

    Auxiliary Circuit (24) 15 Amp

    Spare (25) 5 Amp

    Spare (26) 10 Amp

    Spare (27) 15 Amp

  • 172Maintenance SectionHydraulic System Oil - Change

    i00818900

    Hydraulic System Oil - ChangeSMCS Code: 5056-044

    g00101435Illustration 191

    1. Park the machine on level ground. Lower thebucket to the ground so that the stick is vertical.

    g00102825Illustration 192(1) Bolts(2) Washers(3) Cover

    2. Remove bolts (1), washers (2) and the cover (3)from the top of the hydraulic tank.

    g00104289Illustration 193

    3. Clean the area thoroughly in order to keep dirt outof the screen cover. Clean the area thoroughly inorder to keep dirt out of the fill/vent plug.

    4. Relieve the internal pressure from the hydraulictank by loosening the fill/vent plug. After thepressure is relieved, remove the fill/vent plug.

    g00101446Illustration 194

    5. The oil drain valve is located under the hydraulictank.

    6. Remove the hydraulic tank access cover that islocated under the upper structure. This will allowaccess to the drain valve.

    g00104295Illustration 195

  • 173Maintenance Section

    Hydraulic System Oil - Change

    Note: Refer to Operation and Maintenance Manual,General Hazard Information for information onContaining Fluid Spillage.

    7. Remove the oil drain valve plug.

    g00293719Illustration 196

    8. Install a Swivel Hose with clear plastic tubing inorder to open the drain valve. Drain the oil into asuitable container.

    9. Remove the Swivel Hose in order to close thedrain valve.

    10. Inspect the O-ring. Replace the O-ring if wear ordamage is evident.

    11.Clean the drain plug. Install the drain plug.

    g00101449Illustration 197

    12.Open the access door that is located on the rightside of the machine.

    13.Clean the pump. Clean the hydraulic lines. Cleanthe hydraulic tank.

    g00101490Illustration 198(4) Bolt(5) Washer(6) Cover(7) Spring(8) Screen

    14.Remove bolts (4), washers (5), and cover (6).

    Note: Used filters and used fluids should alwaysbe disposed of according to established localregulations.

    Note: Do not allow spring (7) to fall into the tank.

    15.Remove spring (7) and screen (8).

    Note: Refer to Operation and Maintenance, GeneralHazard Information for information on containingfluid spillage.

    16.Wash the screen in a clean nonflammable solvent.Allow the screen to dry. Inspect the screen.Replace the screen, if the screen is damaged.

  • 174Maintenance SectionHydraulic System Oil - Change

    g00101492Illustration 199(9) O-ring seal(10) O-ring seal

    17. Inspect O-ring seals (9) and (10). Replace theO-ring seals if wear or damage is evident.

    18. Install a new screen and spring (7). Then installcover (6), washers (5), and bolts (4).

    Note: Make sure that the O-ring seals and the springare properly positioned during installation.

    19. Fill the hydraulic system oil tank. Refer toOperation and Maintenance Manual, RefillCapacities.

    20. Inspect the O-ring on the filler plug for damage.Replace the O-ring, if necessary. Clean the fillerplug. Install the filler plug.

    g00104296Illustration 200

    21.Remove the pressure cap.

    g00101462Illustration 201

    22. Inspect the pressure cap. Clean the pressure cap.Replace the pressure cap if damage is evident.

    23. Install the pressure cap.

    g00401382Illustration 202

    Note: Make no attempt to start the engine until thepump has been filled with hydraulic oil. Seriousdamage to the hydraulic components can result.

    24.When the hydraulic oil has been replaced, the airmust be removed from the hydraulic oil system.Use the following procedure to remove the airfrom the hydraulic oil system.

    a. While the engine is stopped, remove hose (11),connector (12), and O-ring (13) from the top ofthe pump. Add oil to the opening of the fill port.

    b. Check O-ring (13) and replace the O-ring if theO-ring is damaged.

    c. Start the engine and operate the engine at lowidle until oil flows out of the fill port.

    d. Install hose (11), connector (12) and O-ring(13) correctly.

    25.Close the access door.

  • 175Maintenance Section

    Hydraulic System Oil Filter - Replace

    26.Start the engine. Operate the engine at idlingspeed for five minutes.

    g00101435Illustration 203

    27.Operate the control levers in order to circulatethe hydraulic oil. Lower the bucket to the groundso that the stick is vertical to the ground. Stop theengine.

    g00400491Illustration 204(A) High Temperature Range(B) Low Temperature Range

    28.Maintain the oil level between the marks on thesight gauge in the appropriate temperature range.

    i00818961

    Hydraulic System Oil Filter -ReplaceSMCS Code: 5068-510

    Replace the Pilot Filter

    g00101449Illustration 205

    1. Open the access door on the right side of themachine.

    g00400487Illustration 206

    2. Clean the area in order to keep dirt out of the filterbase.

    3. Remove the used pilot filter element from the filterbase.

    Note: This element is a cartridge type filter. Theelement cannot be reused.

    Note: Used filters should always be disposed ofaccording to local regulations.

    4. Clean the filter base.

  • 176Maintenance SectionHydraulic System Oil Filter - Replace

    g00101502Illustration 207

    5. Coat the seal of a new pilot filter with cleanhydraulic oil. Install the new pilot filter in the filterbase. Tighten the pilot filter hand tight.

    6. Close the access door.

    Replace the Case Drain Filter

    g00101449Illustration 208

    1. Open the access door on the right side of themachine.

    g00400489Illustration 209

    2. Clean the area in order to keep dirt out of the filterbase.

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

    Note: This element is a cartridge type filter. Theelement cannot be reused.

    Note: Used filters should always be disposed ofaccording to local regulations.

    4. Clean the filter base.

    g00101502Illustration 210

    5. Coat the seal of a new case drain filter with cleanhydraulic oil. Install the new case drain filter in thefilter base. Tighten the case drain filter hand tight.

    6. Close the access door.

    7. Drive the machine slowly for 10 minutes to 15minutes. Move each cylinder evenly throughseveral cycles.

    g00101435Illustration 211

    8. Return the machine to the position that is shownabove. Check the machine for oil leaks.

    9. Stop the engine.

    10.Open the access door on the right side of themachine in order to access the sight gauge.

  • 177Maintenance Section

    Hydraulic System Oil Level - Check

    g00400491Illustration 212(A) High temperature range(B) Low temperature range

    11.Maintain the oil level in the low temperature rangefor a cold machine. Maintain the oil level in thehigh temperature range for a machine that is at anormal operating temperature.

    g00103996Illustration 213

    12.Slowly loosen the filler plug in order to relieve anypressure. Remove the filler plug in order to addoil, if necessary.

    13.Clean the filler plug. Install the filler plug.

    14.Close the access door.

    i00818967

    Hydraulic System Oil Level -CheckSMCS Code: 5050-535

    NOTICENever remove the fill/vent plug from the hydraulic tankif the oil is hot.

    Air can enter the system and cause pump damage.

    g00102817Illustration 214

    The hydraulic oil tank is on the right side of the machine.

    1. Park the machine on level ground. Lower thebucket to the ground with the stick in a verticalposition, as shown.

    g00102818Illustration 215

    2. Open the access door on the right side of themachine.

  • 178Maintenance SectionHydraulic System Oil Return Filter - Replace

    g00400491Illustration 216(A) High temperature range(B) Low temperature range

    3. For a cold machine, maintain the hydraulic oil levelin the low temperature range. For a machine thatis at normal operating temperature, maintain thehydraulic oil level in the high temperature range.

    4. Close the access door.

    g00103996Illustration 217

    Note: Refer to Operation and Maintenance Manual,General Hazard Information for information onContaining Fluid Spillage.

    5. Slowly loosen the filler plug in order to relieve anypressure. Add oil, if necessary.

    6. Check the O-ring seal of the filler plug. Replacethe O-ring seal if the O-ring seal is damaged.

    7. Clean the filler plug and install the filler plug.

    i00674798

    Hydraulic System Oil ReturnFilter - ReplaceSMCS Code: 5068-510-RJ

    Remove the Filter CartridgeThe return filter is a cartridge type filter. The returnfilter reduces the amount of foreign material thatenters the hydraulic system when the filter elementis replaced.

    g00102209Illustration 218

    Note: If the indicator for a Restricted HydraulicReturn Filter comes on, push the reset switch atthe filter case. Run the machine on level groundfor approximately 10 minutes. If the indicator stillcomes on, inspect the filter and replace the filter, ifnecessary.

    g00104227Illustration 219

    1. Loosen the filler plug in order to relieve thehydraulic tank pressure. Tighten the filler plugafter the hydraulic tank pressure is relieved.

    Note: The return filter is located behind the filler plug.

  • 179Maintenance Section

    Hydraulic System Oil Return Filter - Replace

    g00102211Illustration 220(1) Bolts. (2) Washers. (3) Cover. (4) Plug. (5) Filter cartridge.

    2. Remove bolts (1), washers (2), and cover (3).

    Note: Refer to Operation and Maintenance Manual,General Hazard Information for information onContaining Fluid Spillage.

    3. Remove plug (4) in order to release the pressurein filter cartridge (5).

    g00102212Illustration 221

    (5) Filter cartridge. (6) Filter case. (A) Guide.

    4. Pull up the handle at the top of filter cartridge (5)until the filter cartridge contacts guide (A) on filtercase (6).

    g00102214Illustration 222

    5. Turn the filter cartridge counterclockwise by 1/2turn in order to align the projection of the filtercartridge with the notch of the filter case. Pull outthe filter cartridge.

    g00102219Illustration 223

    (7) O-ring.

    6. Inspect the cover and O-ring (7). If either part isdamaged, replace the part.

    7. Inspect the filter cartridge for debris and fordamage. If necessary, replace the filter cartridge.

  • 180Maintenance SectionHydraulic System Oil Return Filter - Replace

    Remove the Filter Element

    g00104507Illustration 224

    (4) Plug. (8) Plate. (18) O-ring.

    1. Make sure that plug (4) is removed. Make surethat all of O-ring (18) is removed from plate (8).

    g00104508Illustration 225

    (8) Plate. (9) Spiral retaining ring.

    2. Use a flat screwdriver in order to remove spiralretaining ring (9).

    g00104510Illustration 226(8) Plate. (10) Shell. (11) O-ring. (12) Filter element.

    3. Hold the filter cartridge with one hand. Grasp thegrip of plate (8) with your other hand. Lift plate(8) in order to separate plate (8) from the filtercartridge.

    4. Remove O-ring (11) from plate (8).

    5. Lift filter element (12) from shell (10).

    6. Pour the remaining oil into a suitable container.

    Clean Shell of Filter Cartridge

    g00104511Illustration 227(13) Slide plate. (14) Blotter Pads. (15) Screws. (19) Port.

    1. Turn shell (10) upside-down.

    2. Remove screws (15).

    3. Remove Blotter Pads (14) from slide plate (13).

    4. Wash the following parts in a clean nonflammablesolvent: plug (4), plate (8), spiral retaining ring (9),shell (10), and Blotter Pads (14). Dry the parts.

    Install the Filter ElementNote: Use the parts found in 137-3635 ServiceKit when installing the filter element and the filtercartridge.

    1. Spray oil to the inside of shell (10) in order toprevent rust.

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

    3. Plate (8) will contact the inside of shell (10). Applygrease to this point.

    4. Apply grease to O-rings inside ports (19) at thebottom of shell (10).

    5. Install new Blotter Pads (14). Tighten the screwsto a torque of 0.4 Nm (3.5 lb in).

  • 181Maintenance Section

    Hydraulic System Oil Return Filter - Replace

    6. Spray oil into the clearance between shell (10)and slide plate (13).

    g00104512Illustration 228(8) Plate. (10) Shell. (16) Boss. (17) Notch.

    7. Turn over shell (10). Apply grease to the twoO-rings on new element (12). Install element (12)into shell (10).

    8. Move boss (16) in alignment with notch (17).Install plate (8) into shell (10).

    9. Install spiral retaining ring (9) into the groove inshell (10).

    10.Apply grease to new O-ring (18). Install O-ring(18) on plug (4).

    11. Install plug (4) into plate (8).

    Install the Filter Cartridge

    g00102220Illustration 229

    (B) Port. (C) Slide plate.

    1. Check that ports (B) at the bottom of the filter caseare closed.

    Note: If the ports are open, rotate slide plate (C)counterclockwise to the stopper in order to fullyclose the ports. When the ports are fully closed, anyremaining oil in the filter case should be completelyremoved.

    g00102221Illustration 230(E) Slide plate. (D) Port.

    2. Check that ports (D) of the filter cartridge are fullyclosed.

    Note: The filter cartridge cannot be installed unlessthe ports are fully closed. If the ports are open, rotateslide plate (E) counterclockwise to the stopper inorder to fully close the ports.

    g00102222Illustration 231

    (F) O-rings.

    3. Check that O-rings (F) have been installed andthat oil has been applied to O-rings (F).

  • 182Maintenance SectionHydraulic System Oil Sample - Obtain

    g00102225Illustration 232(1) Bolts.

    4. Install the filter cartridge into the filter case. Turnthe filter cartridge clockwise by 1/2 turn and pushdown the filter cartridge when the filter cartridgecontacts guide (A).

    5. Install plug (4), cover (3), washers (2), and bolts(1). Tighten bolts (1) to a torque of 29 5 Nm(22 4 lb ft).

    g00104319Illustration 233

    6. To turn off the indicator for a Restricted HydraulicReturn Filter, push the reset switch on the filtercase while the engine start switch is in the ONposition.

    i00998893

    Hydraulic System Oil Sample- ObtainSMCS Code: 5050-008; 7542-008

    g00101628Illustration 234

    Open the access door on the right side of themachine in order to access the sampling valve.

    g00291849Illustration 235

    The hydraulic oil sampling valve is located near thepilot filter.

    Refer to Operation and Maintenance Manual, SOSOil Analysis for more information on obtaining ahydraulic oil sample.

  • 183Maintenance Section

    In-Line Refrigerant Dryer - Check/Replace

    i00824564

    In-Line Refrigerant Dryer -Check/ReplaceSMCS Code: 7322-510; 7322-535

    Personal injury can result from contact with refrig-erant.

    Contact with refrigerant can cause frost bite. Keepface 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 ventilatedarea.

    Personal injury or death can result from inhalingrefrigerant through a lit cigarette.

    Inhaling air conditioner refrigerant gas through alit cigarette or other smoking method or inhalingfumes released from a flame contacting air con-ditioner refrigerant gas, can cause bodily harm ordeath.

    Do not smoke when servicing air conditioners orwherever refrigerant gas may be present.

    Use a certified recovery and recycling cart to prop-erly remove the refrigerant from the air condition-ing system.

    Check

    g00397017Illustration 236

    The in-line refrigerant dryer is located behind a panelon the under side of the cab.

    1. Remove the panel on the under side of the cab inorder to access the refrigerant dryer.

    g00397060Illustration 237

    2. Check moisture indicator (2) on the refrigerantdryer. If the moisture indicator is pink, replace thedryer. Refer to Replacement Procedure for thecorrect procedure. If the moisture indicator is blue,the dryer is functioning correctly.

    3. Install the panel when service is complete.

    Note: The refrigerant dryer should always bechecked at the end of the summer.

    Replacement Procedure1. Stop the engine. Allow the air conditioning systemto remain inactive for five minutes in order toequalize the pressure.

    2. Remove the panel on the under side of the cab inorder to access the refrigerant dryer.

    3. If the refrigerant dryer is equipped withelectrical connections, disconnect the electricalconnections.

    g00397060Illustration 238

    4. Disconnect the IN hose (1) from the oldrefrigerant dryer. Disconnect hose (1) at quickcoupler (4).

  • 184Maintenance SectionIndicators and Gauges - Test

    5. Connect the IN hose (1) that was disconnectedin Step 4 to the IN hose coupler on the newrefrigerant dryer.

    6. Start the engine and operate the air conditioningsystem for one minute in order to evacuate therefrigerant from the old refrigerant dryer.

    Note: This procedure is performed so that theamount of refrigerant charge remains the same in theair conditioning system.

    7. With the air conditioning system in operation,disconnect the OUT hose (3) from the oldrefrigerant dryer. Disconnect hose (3) at quickcoupler (5).

    8. Stop the engine. The air conditioning system mustbe idle for five minutes in order to equalize thepressure.

    9. Connect the OUT hose (3) that was disconnectedin Step 7 to the coupler on the new refrigerantdryer.

    10. If the refrigerant dryer is equipped with electricalconnections, connect the electronics at this time.

    11. Install the panel when service is complete.

    i00107754

    Indicators and Gauges - TestSMCS Code: 7450-081; 7490-081

    g00106777Illustration 239

    1. Look for broken lenses on the gauges, brokenindicator lights, broken switches, and other brokencomponents in the cab.

    2. Start the engine.

    3. Look for inoperative gauges.

    4. Turn on all machine lights. Check for properoperation.

    5. Move the machine forward. Release the travellevers and the travel pedals. The machine shouldstop.

    6. Stop the engine.

    7. Make any repairs that are required beforeoperating the machine.

  • 185Maintenance SectionOil Filter - Inspect

    i00052234

    Oil Filter - InspectSMCS Code: 1308-507; 5068-507

    Inspect A Used Filter for Debris

    g00100013Illustration 240

    The element is shown with debris.

    Use a 4C-5084 Filter Cutter to cut the filter elementopen. Spread apart the pleats and inspect theelement for metal and for other debris. An excessiveamount of debris in the filter element can indicate apossible failure.

    If metals are found in the filter element, a magnet canbe used to differentiate between ferrous metals andnonferrous metals.

    Ferrous metals can indicate wear on steel parts andon cast iron parts.

    Nonferrous metals can indicate wear on thealuminum parts of the engine such as main bearings,rod bearings, or turbocharger bearings.

    Small amounts of debris may be found in the filterelement. This could be caused by friction and bynormal wear. Consult your Caterpillar dealer in orderto arrange for further analysis if an excessive amountof debris is found.

    Using an oil filter element that is not recommendedby Caterpillar can result in severe engine damageto engine bearings, to the crankshaft, and to otherparts. This can result in larger particles in unfilteredoil. The particles could enter the lubricating systemand the particles could cause damage.

    i00094899

    Quick Coupler - LubricateSMCS Code: 6129-086

    Wipe all fittings before you apply lubricant.

    g00104878Illustration 241

    Apply lubricant through the four fittings on the quickcoupler. The quick coupler has two fittings on eachside.

    Note: Do not lubricate the wedge and the wearplates. Friction is needed in order to hold the wedgein place during backfilling.

  • 186Maintenance SectionRadiator Core - Clean

    i00641768

    Radiator Core - CleanSMCS Code: 1353-070

    g00287670Illustration 242

    1. Loosen wing bolts (1) on the front of the radiator.Remove screen (2) from the radiator.

    g00287672Illustration 243

    2. Check the radiator fins for debris.

    3. Remove dust and debris from the radiator fins andfrom the screen of the radiator.

    Compressed air is preferred, but high pressurewater or steam can be used to remove dust andgeneral debris from the radiator. Clean the radiatoraccording to the condition of the radiator.

    See Special Publication, SEBD0518, Know YourCooling System for more detailed informationabout cleaning radiator fins.

    4. Install screen (2) to the radiator, and tighten wingbolts (1).

    i00969587

    Refueling Pump Strainer -Clean(If Equipped)SMCS Code: 1295-070-STR

    g00103988Illustration 244

    1. Open the storage box on the front of the machine.Remove suction hose (1).

    2. Loosen clamp (2) and disconnect strainer (3) fromhose (1).

    3. Clean strainer (3) with a nonflammable solution.Allow the strainer to dry.

    4. Mount strainer (3) on hose (1) and secure thestrainer with clamp (3).

    NOTICETo prevent hose damage, do not coil the hose in a tightradius.

    5. Store suction hose (1) on bar (4). Bar (4) is locatedin the storage box. Use strip (5) to hold the end ofthe hose in place.

    6. Close the storage box.

  • 187Maintenance SectionSeat Belt - Inspect

    i00112638

    Seat Belt - InspectSMCS Code: 7327-040

    g00101563Illustration 245

    When this machine was shipped from Caterpillar,Inc., this machine was equipped with a seat belt andwith a seat belt installation. At the time of installation,the seat belt and the seat belt installation met SAEJ386 JUN85 for an industrial machine and SAEJ386 JUN93. Consult your Caterpillar dealer for allreplacement parts.

    Regardless of appearance, replace the seat belt afterevery three years of use. A date label for determiningthe age of the seat belt is attached to each seat belt.

    Always check the condition of the seat belt and thecondition of the seat belt mounting hardware beforeyou operate the machine. If damage or wear is found,replace either the seat belt or the seat belt mountinghardware before operating the machine.

    i00731002

    Seat Belt - ReplaceSMCS Code: 7327-510

    g00037721Illustration 246

    Regardless of the appearance, replace the seat beltonce during every three year interval.

  • 188Maintenance SectionSwing Bearing - Lubricate

    i00826873

    Swing Bearing - LubricateSMCS Code: 7063-086

    Wipe the fittings before you lubricate the swingbearings.

    g00101569Illustration 247

    The swing bearings are under the base of the boom.

    g00287576Illustration 248

    Apply lubricant through the fittings until the lubricantoverflows the bearing seals.

    i00822248

    Swing Drive Oil - ChangeSMCS Code: 5459-044

    g00101586Illustration 249

    The oil drain plug is under the center of the upperstructure.

    g00104281Illustration 250

    Note: Refer to Operation and Maintenance Manual,General Hazard Information for information onContaining Fluid Spillage.

    1. Remove drain plug (1). Allow the oil to drain into asuitable container.

    2. Use a clean, nonflammable solvent to clean oildrain plug (1). Apply pipe sealant to the plug.

    3. Install oil drain plug (1).

  • 189Maintenance Section

    Swing Drive Oil Level - Check

    g00287627Illustration 251

    4. Remove dipstick (2).

    5. Add the specified quantity of oil through thedipstick tube. See Operation and MaintenanceManual, Refill Capacities.

    g00104248Illustration 252

    6. Make sure that the oil level is maintained betweenthe marks on dipstick (2).

    7. Check the oil that has been drained for metal chipsor metal particles. Consult your Caterpillar dealerif any metal chips or metal particles are found.

    8. Drained materials should always be disposed ofaccording to local regulations.

    i00826799

    Swing Drive Oil Level - CheckSMCS Code: 5459-535-FLV

    g00101622Illustration 253

    The dipstick for the swing drive oil is on the swingdrive at the rear base of the boom.

    g00287629Illustration 254

    1. Remove the dipstick.

    g00102725Illustration 255

    Note: Refer to Operation and Maintenance Manual,General Hazard Information for information thatpertains to Containing Fluid Spillage.

  • 190Maintenance SectionSwing Drive Oil Sample - Obtain

    2. Check the dipstick. Maintain the oil level betweenthe marks on the dipstick. Add oil through thedipstick tube, if necessary.

    3. Insert the dipstick.

    i00858525

    Swing Drive Oil Sample -ObtainSMCS Code: 5459-008

    Refer to Operation and Maintenance Manual, SOSOil Analysis for information that pertains to obtaininga sample of the swing drive oil.

    Obtain a sample of the swing drive oil through theopening of the dipstick.

  • 191Maintenance Section

    Swing Gear - Lubricate

    i00998900

    Swing Gear - LubricateSMCS Code: 7063-086

    NOTICEImproper lubrication can cause damage to machinecomponents.

    To avoid damage, make sure that the proper amountof 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 piniongear of the swing drive and swing internal gear.

    Not enough grease will result in poor gear lubrication.

    g00287633Illustration 256

    Remove the inspection cover that is located near theboom base. Inspect the grease.

    g00287635Illustration 257

    1. Remove bolts (1) and washers (2). Remove cover(3) and gasket (4).

    g00287641Illustration 258

    2. Inspect gasket (4). Replace the gasket if damageis evident.

    3. Check the level of the grease. The grease shouldbe evenly distributed on the floor of the pan.

    Note: Refer to Operation and Maintenance Manual,Refill Capacities for the size of the pan.

    Add grease, as needed. Remove grease, asneeded. Too much grease will result in thedeterioration of the grease because of excessivemovement of the grease. Too little grease willresult in poor lubrication of the swing gear.

    g00101653Illustration 259

    4. Check for contamination and for discoloredgrease.

    5. If the grease is contaminated or discolored withwater, change the grease. Remove plug (5) inorder to allow the water to drain. When youreinstall plug (5), inspect O-ring seal (6). Replacethe O-ring seal if damage is evident.

  • 192Maintenance SectionTrack Adjustment - Adjust

    g00101644Illustration 260

    6. Raise the boom and turn the upper structure by 90degrees. Lower the bucket to the ground.

    7. Repeat Step 3 through Step 6 for one completerevolution.

    8. Install gasket (4), cover (3), washers (2), and bolts(1).

    i00772815

    Track Adjustment - AdjustSMCS Code: 4170-025

    Personal injury or death can result from greaseunder pressure.

    Grease coming out of the relief valve under pres-sure can penetrate the body causing injury ordeath.

    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 andcontact your Caterpillar dealer.

    NOTICEKeeping the track properly adjusted will increase theservice life of the track and drive components.

    Note: The track tension must be set according to thecurrent operating conditions. Keep the track as slackas possible if the soil is heavy.

    Measuring Track Tension

    g00101752Illustration 261

    1. Place a straight edge on the tracks. The straightedge should be long enough to reach from theidler to the carrier roller.

    2. Measure the maximum amount of sag in the track.The sag is measured from the highest point ofthe track grouser to the bottom of the edge. Atrack that is properly adjusted will have a slack of40 to 55 mm (1 5/8 to 2 1/8 inch ).

  • 193Maintenance Section

    Track Adjustment - Adjust

    Tightening the Track

    g00401220Illustration 262The track adjuster is located on the track frame.

    Wipe the fitting before you add grease.

    g00354438Illustration 263

    1. Add grease through valve fitting (1) until thecorrect track tension is reached.

    2. Operate the machine back and forth in order toequalize the pressure.

    3. Check the amount of sag. Adjust the track, asneeded.

    Loosening the Track

    g00401220Illustration 264The track adjuster is located on the track frame.

    g00354441Illustration 265

    1. Loosen relief valve (2) carefully until the trackbegins to loosen. One turn should be themaximum.

    2. Tighten relief valve (2) to 34 Nm (25 lb ft) whenthe desired track tension is reached.

    3. Operate the machine back and forth in order toequalize the pressure.

    4. Check the amount of sag. Adjust the track, asneeded.

    If the correct adjustment cannot be achieved, consultyour Caterpillar dealer.

  • 194Maintenance SectionTrack Adjustment - Inspect

    i00824960

    Track Adjustment - InspectSMCS Code: 4170-040

    g00397520Illustration 266

    Check the track adjustment. Check the track for wearand for excessive dirt buildup.

    If the track appears to be too tight or too loose,see Operation and Maintenance Manual, TrackAdjustment - Adjust.

    i00674980

    Travel Alarm - TestSMCS Code: 7429-081

    You must move the machine in order to test the travelalarm.

    1. Start the engine. Move the hydraulic activationcontrol lever to the UNLOCKED position.

    2. Raise the attachments in order to avoid anyobstacles. Make sure that there is adequateoverhead clearance.

    g00291148Illustration 267

    3. Use the travel levers or the travel pedals to movethe machine forward. The travel alarm shouldsound.

    4. Release the travel levers and the travel pedals inorder to stop the machine.

    5. Use the travel levers and the travel pedals tomove the machine backward. The travel alarmshould sound.

    g00101665Illustration 268

    6. Push the alarm cancel switch that is located onthe electronic monitor panel. The travel alarmshould shut off.

  • 195Maintenance Section

    Undercarriage - Check

    7. Stop the machine. Lower the attachments.Move the hydraulic activation control lever to theLOCKED position. Stop the engine.

    i00059532

    Undercarriage - CheckSMCS Code: 4150-535

    g00101898Illustration 269

    1. Check the carrier rollers, the track rollers, and theidler 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 wearand loose mounting bolts.

    3. Listen for any abnormal noises while you aremoving slowly in an open area.

    4. If abnormal wear exists or abnormal noises orleaks are found, consult your Caterpillar dealer.

  • 196Maintenance SectionV-Belts - Inspect/Adjust/Replace

    i00941066

    V-Belts - Inspect/Adjust/ReplaceSMCS Code: 1357-025; 1357-040; 1357-510;1359-025; 1359-040; 1359-510; 1361-025;1361-040; 1361-510; 1405-025; 1405-040;1405-510; 7320-025; 7320-040; 7320-510

    NOTICEThe V-belt must be tensioned correctly. Failure to ten-sion the belt properly could cause damage to the beltand/or to the air conditioner compressor.

    g00287538Illustration 270

    Your engine can be equipped with the following belts:

    Water pump

    Fan drive

    Alternator

    Air conditioner (if equipped)

    For maximum engine performance and maximumutilization of your engine, inspect the belts for wearand for cracking. Check the belt tension. Adjust thebelt tension in order to minimize belt slippage. Beltslippage will decrease the belt life. Belt slippage willalso cause poor performance of the alternator andof any driven equipment.

    If new belts are installed, recheck the belt adjustmentafter 30 minutes of operation. If two belts or more arerequired for an application, replace the belts in beltsets. If only one belt of a pair is replaced, the newbelt will carry more load. This is due to the fact thatthe older belts are stretched. The additional load onthe new belt could cause the new belt to break.

    Water Pump Belt, Fan Drive Belt,and Alternator Belt

    g00359072Illustration 271

    1. Unlatch the engine hood and open the enginehood.

    g00287535Illustration 272

    (1) Mounting bolt(2) Bracket bolt(3) Alternator

    2. Ap