SEBU7708-08 M

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MAINTENANCE INTERVALSOperation and Maintenance Manual Excerpt

SEBU7708-08March 2009

Operation andMaintenanceManualTH220B, TH330B and TH340BTelehandlersSLA1-Up (Machine)SLB1-Up (Machine)SLC1-Up (Machine)

SAFETY.CAT.COM

SEBU7708-08 119Maintenance Section

Maintenance Interval Schedule

i03512966

Maintenance Interval ScheduleSMCS Code: 7000

Ensure that all safety information, warnings andinstructions are read and understood before anyoperation or any maintenance procedures areperformed.

The user is responsible for the performance ofmaintenance, including all adjustments, the use ofproper lubricants, fluids, filters, and the replacementof components due to normal wear and aging. Failureto adhere to proper maintenance intervals andprocedures may result in diminished performance ofthe product and/or accelerated wear of components.

Use mileage, fuel consumption, service hours, orcalendar time, WHICH EVER OCCURS FIRST,in order to determine the maintenance intervals.Products that operate in severe operating conditionsmay require more frequent maintenance.

Note: Before each consecutive interval is performed,all maintenance from the previous interval must beperformed.

When Required

Axle Breathers - Clean/Replace ......................... 121Battery - Recycle ................................................ 122Battery or Battery Cable - Inspect/Replace ........ 122Boom Telescoping Cylinder Air - Purge .............. 127Boom and Frame - Inspect ................................. 132Cab Air Filter - Clean/Replace ............................ 135Circuit Breakers - Test ........................................ 136Cooling System Pressure Cap - Clean/Replace .. 141Engine Air Filter Primary Element - Clean/Replace ............................................................. 146Engine Air Filter Secondary Element - Replace .. 149Fuel System - Prime ........................................... 155Fuel Tank Cap - Clean ........................................ 156Fuses and Relays - Replace ............................... 158Oil Filter - Inspect ................................................ 162Parking Brake - Adjust ........................................ 162Radiator Core - Clean ......................................... 163Window Washer Reservoir - Fill .......................... 173Window Wiper - Inspect/Replace ........................ 173

Every 10 Service Hours or Daily

Backup Alarm - Test ............................................ 121Braking System - Test ......................................... 134Cooling System Coolant Level - Check .............. 139Engine Oil Level - Check .................................... 150Fuel System Water Separator - Drain ................. 156Fuel Tank Water and Sediment - Drain ............... 157Indicators and Gauges - Test .............................. 161Seat Belt - Inspect .............................................. 166Tire Inflation - Check ........................................... 167

Transmission and Hydraulic System Oil Level -Check ................................................................ 170Wheel Nut Torque - Check .................................. 173Windows - Clean ................................................. 173Work Tool - Inspect/Replace ............................... 174

Every 50 Service Hours or Weekly

Pulley for Boom Extension Chain - Lubricate ..... 163Pulley for Boom Retraction Chain - Lubricate ..... 163

Every 100 Service Hours or Monthly

Longitudinal Stability Indicator - Test .................. 161

Every 250 Service Hours

Cooling System Coolant Sample (Level 1) -Obtain ............................................................... 140Engine Oil Sample - Obtain ................................ 150

Initial 500 Hours (for New Systems, RefilledSystems, and Converted Systems)

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 140

Every 500 Service Hours

Differential Oil Sample - Obtain .......................... 145Final Drive Oil Sample - Obtain .......................... 154Transmission and Hydraulic System Oil Sample -Obtain ............................................................... 171

Every 500 Service Hours or 6 Months

Boom Chain Tension - Check/Adjust .................. 124Boom Cylinder Pin - Lubricate ............................ 126Boom Head Section - Lubricate .......................... 126Boom Head Section - Lubricate .......................... 126Boom Pivot Shaft - Lubricate .............................. 126Compensating Cylinder Bearing - Lubricate ....... 136Differential Oil Level - Check .............................. 144Drive Shaft Spline - Lubricate ............................. 145Drive Shaft Universal Joint Bolts - Check ........... 146Engine Air Filter Primary Element - Clean/Replace ............................................................. 146Engine Air Filter Primary Element - Replace ...... 149Engine Air Filter Secondary Element - Replace .. 149Engine Oil and Filter - Change ........................... 151Final Drive Oil Level - Check .............................. 153Fork Leveling Cylinder Pin - Lubricate ................ 155Frame Leveling Cylinder Pin - Lubricate ............. 155Longitudinal Stability Indicator - Calibrate .......... 161

Every 1000 Service Hours or 1 Year

Belt - Inspect/Replace ......................................... 122Boom Wear Pad Clearance - Inspect/Adjust ...... 130Differential Oil - Change ..................................... 143Final Drive Oil - Change ..................................... 153Rollover Protective Structure (ROPS) and FallingObject Protective Structure (FOPS) - Inspect ... 165

120 SEBU7708-08Maintenance SectionMaintenance Interval Schedule

Transmission and Hydraulic System Oil -Change ............................................................. 167Transmission and Hydraulic System Oil Filter -Replace ............................................................. 169Work Tool - Inspect/Replace ............................... 174

Every 2000 Service Hours or 2 Years

Engine Valve Lash - Check ................................. 152Refrigerant Dryer - Replace ................................ 164Transmission and Hydraulic System Tank Breather -Clean ................................................................. 172Transmission and Hydraulic System Tank Breather -Clean ................................................................. 172Turbocharger - Inspect ........................................ 172

Every Year

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 140

Every 3 Years After Date of Installation orEvery 5 Years After Date of Manufacture

Seat Belt - Replace ............................................. 166


Boom Chain - Inspect/Lubricate ......................... 123Cooling System Water Temperature Regulator -Replace ............................................................. 142Engine Mounts - Inspect ..................................... 150


Cooling System Coolant Extender (ELC) - Add .. 139

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 137


Axle Breathers - Clean/Replace

i01922221

Axle Breathers - Clean/ReplaceSMCS Code: 3278-070-BRE; 3278-510-BRE

1. Park the machine on level ground. Fully retractthe boom and fully lower the boom. Move thetransmission control to the NEUTRAL position andensure that the parking brake is engaged. Shutoff the engine.

g01000308Illustration 169Front axle breather for the 220B and the 330B telehandlers

g01000311Illustration 170Front axle breather for the 340B telehandler

g00950516Illustration 171Rear axle breather

2. Clean the area around the breathers. Remove thebreathers from the front and rear axles.

3. Wash the breathers in clean nonflammablesolvent. Wipe the breathers dry and check thebreathers for damage.

4. Replace the breathers if the breathers aredamaged. Install the clean breathers back into theaxles.

i01565564

Backup Alarm - TestSMCS Code: 7406-081

The backup alarm is mounted at the rear of themachine.

Turn the engine start switch to the ON position inorder to perform the test.

Apply the service brake. Move the transmissioncontrol lever to the REVERSE position.

The backup alarm should start to sound immediately.The backup alarm will continue to sound until thetransmission control lever is moved to the NEUTRALposition or to the FORWARD position.

The backup alarm has one sound level. The soundlevel is not adjustable.

122 SEBU7708-08Maintenance SectionBattery - Recycle

i00993589

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

i01864907

Battery or Battery Cable -Inspect/ReplaceSMCS Code: 1401-040; 1401-510; 1402-040;1402-510

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

2. The battery disconnect switch (if equipped) islocated in the engine compartment above thebattery. Turn the key for the battery disconnectswitch to the OFF position. Remove the key. Referto Operation and Maintenance Manual, “BatteryDisconnect Switch” for further information.

3. Disconnect the negative battery cable at thebattery disconnect switch.

Note: Some machines are equipped with twobatteries. Do not allow the disconnected batterycable to contact the battery disconnect switch or themachine.

4. Disconnect the negative battery cable from thebattery.

5. Disconnect the positive cable at the battery end.

6. Inspect the battery terminals for corrosion. Inspectthe battery cables for wear or damage.

7. If necessary, make repairs. If necessary, replacethe battery cables, the battery or the batterydisconnect switch.

8. Connect the positive cable at the battery end.

9. Connect the negative battery cable at the battery.

10.Connect the negative battery cable at the batterydisconnect switch.

11. Install the key for the battery disconnect switch.Turn the battery disconnect switch to the ONposition.

i02293711

Belt - Inspect/ReplaceSMCS Code: 1397-040; 1397-510

InspectNote: If a new belt is installed, check the film onthe belt tensioner (2) after 30 minutes of operation.A belt is considered to be used after 30 minutes ofoperation.

1. Park the machine on level ground. Fully retractthe boom and fully lower the boom. Move thetransmission control to the NEUTRAL position andengage the parking brake. Shut off the engine.

2. Open the engine enclosure.

g00953133Illustration 172


Boom Chain - Inspect/Lubricate

g01148415Illustration 173Equipped with a reversible fan

(S/N: SLA)(S/N: SLB)

3. Inspect the condition of belt (1).

4. Replace the belt if any of the following conditionsexist:

• excessive cracking

• excessive wear

• excessive damage

5. Inspect the free arm stop of the belt tensioner (2).The free arm stop must be aligned with the blackline which is on the decal of the belt tensioner(2). If the free arm stop is in the red area, replacethe belt.

6. Close the engine enclosure.

Replace1. Park the machine on level ground. Fully retractthe boom and fully lower the boom. Move thetransmission control to the NEUTRAL position andengage the parking brake. Shut off the engine.


3. Turn the battery disconnect switch to the OFFposition.

4. Remove the retaining bolts for the fan guard. Slidethe guard out of the engine enclosure.

5. Release the tension on the belt (1). Insert a12.7 mm (0.50 inch) ratchet into the square holein the belt tensioner (2) and pry the belt tensionerin a clockwise direction.

6. Remove the belt from the pulleys. Feed the beltover the fan.

7. Install the new belt around the pulleys. Pry thebelt tensioner in a clockwise direction. Install thebelt around the belt tensioner. Release the belttensioner in order to put tension on the belt. Therouting of the belt is shown in Illustration 172 andIllustration 173.

8. Install the fan guard and tighten the retaining boltsto a torque of 15 ± 3 N·m (11.1 ± 2.2 lb ft).

9. Turn the battery disconnect switch to the ONposition.

10.Close the engine enclosure.

i01881146

Boom Chain - Inspect/LubricateSMCS Code: 6460-040-CX; 6460-086-CX

S/N: SLC1-Up

Note: The information that follows will only relate tomachines that have a three-section boom.


The boom extension chain and boom retraction chainmust be removed from the boom for inspection. Afterremoval, measure the chains for wear. Chains whichare serviceable must be lubricated before reinstallingthe chains. For the correct procedure, refer to theHydraulic System Systems Operation, Testing andAdjusting, “Boom Chain - Clean/Inspect/Lubricate” orrefer to your Caterpillar dealer for details.

124 SEBU7708-08Maintenance SectionBoom Chain Tension - Check/Adjust

i02408836

Boom Chain Tension -Check/AdjustSMCS Code: 5917-025-BM; 5917-535-BM

S/N: SLC1-Up

You must read the warnings and instructionswhich are contained in the safety section of thismanual. Before you perform any operation ormaintenance procedures ensure you understandthe warnings and instructions.

Check Condition1. Park the machine on level ground. Fully retractthe boom and lower the boom.

2. Remove the cover from the rear of the chassis.

3. A limited inspection of the chains can be madethrough the rear of the boom. The boom extensionchain can be inspected by fully extending theboom and looking on top of the intermediatesection. If the chains are corroded, the chainsmust be removed from the boom for cleaning anda full inspection. If the chains require lubricant,the chains must be removed from the boomfor cleaning and a full inspection. Refer to theHydraulic System Systems Operation, Testing andAdjusting, “Boom Chain - Clean/Inspect/Lubricate”or consult your Caterpillar dealer.

4. Install the cover on the rear of the boom.

Check and Adjust the ChainTension1. Slacken the extension chain and the retractionchain slightly. Raise the boom to the maximumangle and retract the boom. This ensures that allsections of the boom are fully retracted. If theretraction chain requires adjustment and the boomis retracted in a lowered position, all the sectionswill not fully retract.

The boom can fall if a control is moved or if a hy-draulic component fails. This can cause personalinjury or death. Support the boom with stands. Donot rely on the cylinder to hold the boom up.


2. Lower the boom to the horizontal position andinstall a suitable stand under the first sectionin order to prevent the boom from fallingunexpectedly. To properly support the boom, usethe following tools:

Table 13

Required Tools

Part Number Description Quantity

8S-7641 Tube 1

4C-6486 Stand 1

8S-7615 Pin 1

8S-7625 Collar 1

8S-8048 Saddle 1

3. Lower the boom to a position just above the standand stop the engine.



Boom Chain Tension - Check/Adjust


4. Set the minimum distance to 224 mm (8.8 inch)between boom section 2 and boom section 3. Themaximum allowable distance is 234 mm (9.2 inch).Tighten extension chain (1) in order to movesection 3 outward. Tighten retraction chain (2) inorder to move section 3 inward. If the distance issignificantly more than 224 mm (8.8 inch), slackenboth chains and refer to Step 1.

5. After setting the distance to the required tolerance,tighten the extension chain to 20 N·m (15 lb ft).Maintain the distance between boom section 2and boom section 3 while you tighten the chain.

6. Tighten the retraction chain to 15 N·m (11 lb ft).

7. Tighten the extension chain to 95 ± 3 N·m(70 ± 2 lb ft).

8. Tighten the retraction chain to 60 ± 3 N·m(44 ± 2 lb ft).

9. Extend the boom and retract the boom severaltimes. Check the torque for the extension chain.Check the torque for the retraction chain. Checkthe distance between boom section 2 and boomsection 3. All specifications must be maintainedwithin tolerance.

10. Install the locknut for the extension chain. Torquethe locknut for the extension chain to 95 ± 3 N·m(70 ± 2 lb ft).

11. Install the locknut for the retraction chain. Torquethe locknut for the retraction chain to 60 ± 3 N·m(44 ± 2 lb ft).

12.Check the shackles on both chains. If necessary,adjust the shackles in order to set the shackleshorizontally.

13.Remove the stand and lower the boom.

Measure the Chain for WearNominal pitch of the link equals 25.4 mm (1 inch).

Nominal height of the plate equals 24.1 mm(0.95 inch).

1. Fully retract the boom. Position the boomhorizontally.

2. Extend the boom by 2 m (6 ft 7 inch) or extend theboom to the section of chain that most frequentlypasses over the boom extension chain pulley.

Do not retract the boom sections before youbegin to measure the chains.


3. Use a caliper in order to measure the height ofinner plate (A) and the height of outer plate (A)over 15 pitches of the selected worn section ofchain. If any inner plate or any outer plate showsa reduction in height of more than 5% wear, allchains must be replaced. Also, if the measurementis less than 22.89 mm (0.901 inch), all chainsmust be replaced.

4. Use a 6V-0028Wear Gauge As (CHAIN) in orderto measure the chain between the 16 pin centersof the selected worn section (B). The nominallength of 16 pin centers is 381 mm (15 inch). Ifthe measurement shows an elongation of morethat 2%, all chains must be replaced. Also, ifthe measurement is greater than 388.6 mm(15.30 inch), all chains must be replaced.

126 SEBU7708-08Maintenance SectionBoom Cylinder Pin - Lubricate

i01867607

Boom Cylinder Pin - LubricateSMCS Code: 5456-086-PN


There is a boom raise cylinder under the boom.Lubricate the boom cylinder pin through the fitting atthe rod end of the cylinder.

i01919773

Boom Head Section - LubricateSMCS Code: 6501-086

S/N: SLA1-Up

S/N: SLB1-Up


Lubricate the boom head through lubrication fittings(1), (2) and (3). Tilt the work tool forward in order toaccess lubrication fitting (4.). Lubricate fitting (4).

i01925273

Boom Head Section - LubricateSMCS Code: 6501-086

S/N: SLC1-Up


Lubricate the boom head through the lubricationfitting.

i01865009

Boom Pivot Shaft - LubricateSMCS Code: 6501-086-JF


Location of the pivot shaft for the boom


Boom Telescoping Cylinder Air - Purge


Lubricate the pivot shaft for the boom through thelubrication fitting. The lubrication fitting is located ontop of the pivot shaft for the boom.

i01618057

Boom Telescoping CylinderAir - PurgeSMCS Code: 5486-542-AI

It may be necessary to purge air from the boomextend cylinder after the hydraulic oil has beenchanged. It may also be necessary to purge air fromthe boom extend cylinder after any disassembly ofhydraulic system components.

Normally, the hydraulic system will purge air from theboom extend cylinder but air can be trapped. Air inboom extend cylinder can cause erratic boom motion.

1. If necessary, warm the hydraulic oil by raising theboom and lowering the boom.


2. Retract and lower the boom. Position the machineon a down slope. Engage the parking brake.

3. Fully extend the boom and retract the boom sixtimes. This will purge air from the cylinders.

4. Move the machine back to level ground and checkthe operation of the boom motion.

i02599084

Boom Wear Pad Clearance -Inspect/AdjustSMCS Code: 6460-025-JP; 6460-040-JP

S/N: SLA1-Up

S/N: SLB1-Up

The clearance between the wear pads and the boomsection should be checked at more frequent intervalswhen the machine is operated in severe conditions.

Note: Sand or grit particles can cause acceleratedwear to the wear pads.

1. Park the machine in a clear area on level groundand chock the wheels.



2. Raise the boom to the horizontal position and fullyextend the boom. Install a suitable stand underthe first section in order to prevent the boom fromfalling unexpectedly. Do not support the secondsection. To properly support the boom, use thefollowing tools:

128 SEBU7708-08Maintenance SectionBoom Wear Pad Clearance - Inspect/Adjust

Table 14

Required Tools


8S-7641 Tube 1

4C-6486 Stand 1

8S-7615 Pin 1

8S-7625 Collar 1

8S-8048 Saddle 1

3. Stop the engine.


4. Measure clearances (1) between the wear padsand the side of the boom sections at each side.

5. Measure clearances (2) between the wear padsand the top of the boom sections.


6. Raise the boom and remove the stand. Fullyretract the boom and support the boom in thehorizontal position. In order to support the boom,install the stand under the second section or installcribbing under the quick coupler.


7. Remove the cover from the rear of the chassisand measure clearances (3) between the rearwear pads and the side of the boom sections ateach side.

8. Measure clearances (4) between the rear wearpads and the top of the boom sections.

9. The clearance at each location must not exceed1.5 mm (0.06 inch). If the clearances areexcessive, adjustments must be made.

AdjustmentNote: The bolts that secure different wear pads arenot identical lengths. Do not mix the bolts. Cleanall used bolts. Before installation, apply thread lockcompound to bolts that secure wear pads.


1. Remove bolts (5) that secure the rear top wearpads. Install sufficient shims in order to reducethe clearance to 0.75 mm (0.030 inch). Apply9S-3263 Thread Lock Compound to the bolts.Tighten the bolts to a torque of 60 ± 5 N·m(44 ± 4 lb ft).


Boom Wear Pad Clearance - Inspect/Adjust

2. Remove bolts (6) that secure the rear side wearpads. Install sufficient shims in order to reduce theclearance to 0.75 mm (0.030 inch) at each side.Install sufficient shims in order to produce an equalclearance between the boom sections at eachside. It may be necessary to install more shimsat one side than the other side. Apply 9S-3263Thread Lock Compound to the bolts. Tighten thebolts to a torque of 60 ± 5 N·m (44 ± 4 lb ft).


3. Raise the boom sufficiently above the stand.Fully extend the boom and lower the boom to thehorizontal position. Support the boom under thesecond section.


4. Remove bolts (7) that secure the bottom wearpads. Install sufficient shims in order to reducethe clearance to 0.75 mm (0.030 inch). Apply9S-3263 Thread Lock Compound to the bolts.Tighten the bolts to a torque of 60 ± 5 N·m(44 ± 4 lb ft).


5. Remove bolts (8) that secure the side wear pads.Install sufficient shims in order to reduce theclearance to 0.75 mm (0.030 inch) at each side.Install sufficient shims in order to produce an equalclearance between the wear pads and the boomsections at each side. It may be necessary toinstall more shims at one side than the other side.Apply 9S-3263 Thread Lock Compound to thebolts. Tighten the bolts to a torque of 60 ± 5 N·m(44 ± 4 lb ft).

6. Fully extend and retract the boom at angles of 0degrees, 45 degrees and 70 degrees. The boomoperation must be smooth. If the boom operationis not smooth, operate the boom with a load of500 kg (1100 lb) on the attachment. Fully extendthe boom and retract the boom at an angle of 45degrees. Repeat ten times.


130 SEBU7708-08Maintenance SectionBoom Wear Pad Clearance - Inspect/Adjust

7. Extend the boom and lower the work tool to theground. Check the temperature of the top surfacesof number 1 boom section and number 2 boomsection. Check the temperature of the wear padsat opposite locations at positions (A). Both sidesof each section should feel the same temperature.If necessary, increase the thickness of the shimsunder the rear wear pad which is in contact withthe cool side of the boom section. Alternatively,decrease the thickness of the shims under thefront wear pad which is in contact with the hot sideof the boom section.


i02411842

Boom Wear Pad Clearance -Inspect/AdjustSMCS Code: 6460-025-JP; 6460-040-JP

S/N: SLC1-Up

The clearance between the wear pads and the boomsection should be checked at more frequent intervalswhen the machine is operated in severe conditions.

Note: Sand or grit particles can cause acceleratedwear to the wear pads.

1. Park the machine in a clear area on level groundand chock the wheels.



2. Raise the boom to the horizontal position and fullyextend the boom. Install a suitable stand underthe first section in order to prevent the boomfrom falling unexpectedly. Do not support thesecond and third sections. To properly supportthe boom, use the following tools:

Table 15

Required Tools


8S-7641 Tube 1

4C-6486 Stand 1

8S-7615 Pin 1

8S-7625 Collar 1

8S-8048 Saddle 1

3. Stop the engine.


4. Measure clearances (1) between the wear padsand the side of the boom sections at each side.

5. Measure clearances (2) between the wear padsand the top of the boom sections.



Boom Wear Pad Clearance - Inspect/Adjust

6. Raise the boom and remove the stand. Fullyretract the boom and support the boom in thehorizontal position. In order to support the boom,install the stand under the third section or installcribbing under the quick coupler.


7. Remove the cover from the rear of the chassisand measure clearances (3) between the rearwear pads and the side of the boom sections ateach side.

8. Measure clearances (4) between the rear wearpads and the top of the boom sections.

9. The clearance at each location must not exceed1.5 mm (0.06 inch). If the clearances areexcessive, adjustments must be made.

AdjustmentNote: The bolts that secure different wear pads arenot identical lengths. Do not mix the bolts. Cleanall used bolts. Before installation, apply thread lockcompound to bolts that secure wear pads.


1. Loosen bolts (5) that secure the rear top wearpads. Install sufficient shims in order to reduce theclearance to 0.75 mm (0.030 inch). Tighten thebolts to a torque of 75 ± 5 N·m (55 ± 4 lb ft).

2. Remove bolts (6) that secure the rear side wearpads. Install sufficient shims in order to reducethe clearance to 0.75 mm (0.030 inch) at eachside. Install sufficient shims in order to producean equal clearance between the boom sectionsat each side. It may be necessary to install moreshims at one side than the other side. Tighten thebolts to a torque of 75 ± 5 N·m (55 ± 4 lb ft).


3. Raise the boom sufficiently above the stand.Fully extend the boom and lower the boom to thehorizontal position. Support the boom under thethird section.


4. Remove bolts (7) that secure the bottom wearpads. Install sufficient shims in order to reduce theclearance to 0.75 mm (0.030 inch). Tighten thebolts to a torque of 75 ± 5 N·m (55 ± 4 lb ft).

132 SEBU7708-08Maintenance SectionBoom and Frame - Inspect


5. Remove bolts (8) that secure the side wear pads.Install sufficient shims in order to reduce theclearance to 0.75 mm (0.030 inch) at each side.Install sufficient shims in order to produce anequal clearance between the wear pads and theboom sections at each side. It may be necessaryto install more shims at one side than the otherside. Tighten the bolts to a torque of 75 ± 5 N·m(55 ± 4 lb ft).

6. Fully extend and retract the boom at angles of 0degrees, 45 degrees and 70 degrees. The boomoperation must be smooth. If the boom operationis not smooth, operate the boom with a load of500 kg (1100 lb) on the attachment. Fully extendthe boom and retract the boom at an angle of 45degrees. Repeat ten times.


7. Extend the boom and lower the work tool tothe ground. Lower the boom to the ground andfully extend the boom. Check the temperature ofthe top surfaces of number 1 boom section andnumber 2 boom section. Check the temperatureof the wear pads at opposite locations at positions(A) and at positions (B). Both sides of each sectionshould feel the same temperature. If necessary,increase the thickness of the shims under the rearwear pad which is in contact with the cool sideof the boom section. Alternatively, decrease thethickness of the shims under the front wear padwhich is in contact with the hot side of the boomsection.


i02411328

Boom and Frame - InspectSMCS Code: 6501-040; 7050-040

In order to help minimize unexpected, costly repairsand downtime, inspections need to be carried out ona regular basis. The interval between the inspectionsdepends on factors. These factors are the age ofthe machine, the severity of the application, loading,routine servicing which has been carried out on themachine and the operating conditions.

More frequent inspections will be required of oldermachines and machines that are used in particularlysevere applications.

If the machine has been involved in any kind ofaccident the machine must be taken out of serviceimmediately. The machine must be inspected again.

To perform a proper inspection, the machine must bethoroughly cleaned. It is impossible to inspect themachine properly if the machine is dirty.

Early detection and repair of faults will ensurecontinued operation of the machine. Also, earlydetection and repair will improve the availability ofthe machine. Repair of faults will also reduce the riskof accidents.

The machine should only be repaired by a qualifiedCaterpillar dealer. However, if you decide to carry outyour own repairs, consult your Caterpillar dealer forthe recommended repair techniques.


Boom and Frame - Inspect

g00861901Illustration 203Main frame and support cradle

Retract the boom and raise the boom away from themain frame and support cradle (1). Support the boomwith a suitable stand. To properly support the boom,use the following tools:

Table 16

Required Tools


8S-7641 Tube 1

4C-6486 Stand 1

8S-7615 Pin 1

8S-7625 Collar 1

8S-8048 Saddle 1

Inspect the complete main frame and the supportcradle. Inspect the main frame and the support cradleparticularly in welded structures.

Pay particular attention to the mounting points forthe following parts:

• Boom

• Cab

• Axles

• Engine

• Transmission

• Towing attachment (if equipped)

• Mountings on the frame

• Stabilizers (if equipped)

• Tie down lugs

g00836172Illustration 204Stabilizer and rollover protection structure

Lower stabilizers (2) until the stabilizer pads aretouching the ground. Inspect each stabilizer fully.Inspect the beams, stabilizer pads, mountinghardware, cylinders and the pivot pins.

If equipped, inspect Rollover Protection Structure(ROPS) (3) or inspect Falling Objects ProtectionStructure (FOPS) (3). Inspect the ROPS or the FOPScarefully. Do not attempt to straighten the structure.Do not attempt to repair the structure by welding.Consult your Caterpillar dealer if damage is found tothe ROPS or to the FOPS.


Boom and quick coupler

Inspect all sections of boom (4). Inspect the boomafter the boom is extended fully and the work tool ison the ground.

Completely inspect quick coupler (5). Also, inspectthe work tool.

134 SEBU7708-08Maintenance SectionBraking System - Test

g00836176Illustration 206Pivot pins and anchor points

Inspect all pivot pins and inspect all anchor pointsfor wear.

i02294939

Braking System - TestSMCS Code: 4250-081

Service BrakeCheck the area around the machine. Make sure thatthe area is clear of personnel and obstacles.

Check the brakes on a dry, level surface.

Fasten the seat belt before you check the brakes.

The following procedure is used in order to determineif the service brake is functional. This procedureis not intended to measure the maximum brakeperformance. The brake holding torque that isrequired to sustain an engine torque at a specificengine rpm varies depending on the machineconfiguration. The variations are the differences inthe engine setting, in the power train efficiency, andin the brake holding ability, etc.

Test Procedure

1. Remove the work tool and park the machine inthe travel position.

2. Start the engine and disengage the parkingbrake. Place the transmission in FIRST GEARFORWARD.

3. Apply the service brake and fully depress theaccelerator pedal in order to increase the enginespeed.

4. The machine should remain stationary during thistest.

5. Switch off the engine and engage the parkingbrake.

If the machine moved while testing the servicebrakes, contact your Caterpillar dealer.

Have the dealer inspect, and if necessary repairthe service brakes before returning the machineto operation. Failure to have the service brakesinspected and repaired can cause injury or death.

Reference: See Systems Operation, Testing andAdjusting, RENR5190, “TH220B, TH330B, TH340B,TH350B, 355B, TH360B, TH460B, TH560B andTH580B Telehanders Braking System”, “ServiceBrake Control - Check and Adjust” for moreinformation.

Parking BrakeCheck the area around the machine. Make sure thatthe area is clear of personnel and obstacles.

Check the brakes on a dry, level surface.

Fasten the seat belt before you check the brakes.

The following procedure is used in order to determineif the parking brake is functional. This procedureis not intended to measure the maximum brakeperformance. The brake holding torque that isrequired to sustain an engine torque at a specificengine rpm varies depending on the machineconfiguration. The variations are the differences inthe engine setting, in the power train efficiency, andin the brake holding ability, etc.

Test Procedure

1. Start the engine.

2. Engage the parking brake.

3. If the machine is equipped with a standardtransmission, move the transmission control leverin the following pattern:

• SECOND

• NEUTRAL

• SECOND

This is done in order to override the transmissionneutralizer for this test.

Note: The indicator light for the parking brake shouldcome on.


Cab Air Filter - Clean/Replace

4. If the machine is equipped with a power shifttransmission, move the transmission control leverin the following pattern:

• SECOND GEAR FORWARD

• NEUTRAL

• SECOND GEAR FORWARD

This is done in order to override the transmissionneutralizer for this test.

Note: The indicator light for the parking brake shouldcome on.

5. Gradually increase the engine speed to high idle.The machine should not move.

If the machine begins to move, reduce the enginespeed immediately and apply the service brakepedal.

6. Reduce the engine speed. Move the transmissioncontrol lever to NEUTRAL.

If the machine moved during the test, performthe maintenance procedure Operation andMaintenance Manual, “Parking Brake - Adjust”.

i02412631

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

There are two cab air filters.

Primary Cab Air Filter


1. The primary cab air filter is located behindprotection cover (3) on the left side of the cab. Inorder to open the protection cover, unlock lock(2) and turn lock (4) counterclockwise. Then, pulllatch (1) outward.


2. Open filter cover (6) by removing retaining screw(5).

3. Remove the filter from behind filter cover (6).

4. If the air filter is not damaged, clean the air filterwith pressurized air. The maximum air pressurefor cleaning is 205 kPa (30 psi).

Direct pressurized air along the pleats from nocloser than 160 mm (6 inch) from the air filter.

If the air filter is damaged, replace the air filter.

136 SEBU7708-08Maintenance SectionCircuit Breakers - Test

Secondary Cab Air FilterThe secondary cab air filter is located inside the cab.The filter is on the rear wall of the cab behind the seat.


1. Open filter cover (7) by removing retaining screws(8).

2. Remove the filter from the filter housing.

3. If the air filter is not damaged, clean the air filterwith pressurized air. The maximum air pressurefor cleaning is 205 kPa (30 psi).

Direct pressurized air along the pleats from nocloser than 160 mm (6 inch) from the air filter.

If the air filter is damaged, replace the air filter.

i01906654

Circuit Breakers - TestSMCS Code: 1420-081

The circuit breakers are located under theengine hood on the front right side of the enginecompartment.


Main Circuit Breaker (1) – The maincircuit breaker is 120 amp.

Alternator Circuit Breaker (2) – Thealternator circuit breaker is 105 or 135 amp.

Key Start Breaker (3) – The key startbreaker is 60 amp.

Reset the circuit breaker if the breaker trips. Push inthe button in order to reset the circuit. If the buttondoes not remain depressed or the circuit breakertrips soon after being reset, check the appropriateelectrical circuit. Repair the electrical circuit, ifnecessary.

i01865200

Compensating CylinderBearing - LubricateSMCS Code: 5816-086-BD


There is a compensating cylinder under the boom.Lubricate the compensating cylinder pin through thefitting at the head end of the cylinder.


Cooling System Coolant (ELC) - Change

i02429541

Cooling System Coolant (ELC)- ChangeSMCS Code: 1395-044-NL

Personal injury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant orsteam. Any contact can cause severe burns.

Remove filler cap slowly to relieve pressure onlywhen engine is stopped and radiator cap is coolenough to touch with your bare hand.

Do not attempt to tighten hose connections whenthe coolant is hot, the hose can come off causingburns.

Cooling SystemConditioner contains alkali. Avoidcontact with skin and eyes.

NOTICEDo not change the coolant until you read and under-stand the material found in the Special Publication,SEBU6250, “Caterpillar Machine Fluids Recommen-dations”. Failure to do so could result in damage tothe cooling systems components.

NOTICEMixing ELC with other products reduces the effective-ness of the coolant and shortens coolant life. Use onlyCaterpillar products or commercial products that havepassed the Caterpillar EC-1 specifications for pre-mixed or concentrate coolants. Use only CaterpillarExtender with Caterpillar ELC. Failure to follow theserecommendations could result in the damage to cool-ing systems components.

If ELC cooling system contamination occurs see thetopic Extended Life Coolant (ELC) in the Special Pub-lication, SEBU6250, “Caterpillar Machine Fluids Rec-ommendations”.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

If the coolant in the machine is changed fromextended life coolant to another type of coolant,consult your Caterpillar dealer.

1. Allow the engine to cool.


2. Loosen pressure cap (1) from the coolant tankslowly in order to release pressure. Remove thepressure cap.


138 SEBU7708-08Maintenance SectionCooling System Coolant (ELC) - Change

3. Loosen drain valve (2) that is located at the bottomright corner of the radiator. Drain the coolant into asuitable container.


4. Remove coolant drain plug (3) that is locatedin the engine block above the starter. Drain thecoolant into a suitable container.

Note: Check the threads of the drain plug fordamage. Check the sealant on the drain plug fordamage. The drain plug can be reused if threads arenot damaged and the sealant is not damaged.


5. Loosen hose clamp (5) that is located on thehydraulic oil cooler. Remove hose (4). Allow thecoolant to drain into a suitable container.


6. If the machine is equipped with a cab heater,turn the heater control that is located inside thecab to the HOT position. Loosen hose clamp (6).Remove hose (7). Allow the coolant to drain into asuitable container.

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

8. Close drain valve (2).

9. Reinstall coolant drain plug (3) in the engine blockabove the starter. Tighten the plug.

10.Reinstall hoses (4) and (7). Tighten clamps (5)and (6).

NOTICEAdd the coolant solution at a maximum rate of fiveliters per minute. This will reduce the chance of trap-ping air inside the engine block. A large amount oftrapped air can cause localized heating to occur uponstart-up. Localized heating may result in engine dam-age, which may lead to failure of the engine.

11.Add the Extended Life Coolant into the coolanttank. Refer to the following topics:

• Special Publication, SEBU6250, “CaterpillarMachine Fluids Recommendations”, “CoolingSystem Specifications”

• Operation andMaintenanceManual, “Capacities(Refill)”

12.Start the engine. Operate the engine without thepressure cap for the coolant tank until the coolanttemperature regulator opens and the coolant levelstabilizes.

13.Maintain the coolant level up to the FULL markon the coolant tank.


Cooling System Coolant Extender (ELC) - Add

14. Inspect the gasket of the pressure cap. If thegasket is damaged, replace the cap.

15. Install the pressure cap on the coolant tank.

16.Stop the engine.

i01662174

Cooling System CoolantExtender (ELC) - AddSMCS Code: 1352-544-NL






When a Caterpillar Extended Life Coolant (ELC)is used, an extender must be added to the coolingsystem. Refer to the Operation and MaintenanceManual, “Maintenance Interval Schedule” for theproper service interval. The amount of extender isdetermined by the cooling system capacity.

Table 17

Caterpillar Extender (ELC)

Cooling System Capacity Recommended Amountof Caterpillar Extender

22 to 30 L (6 to 8 US gal) 0.57 L (20 oz)

30 to 38 L (8 to 10 US gal) 0.71 L (24 oz)

38 to 49 L (10 to 13 US gal) 0.95 L (32 oz)

49 to 64 L (13 to 17 US gal) 1.18 L (40 oz)

64 to 83 L (17 to 22 US gal) 1.60 L (54 oz)

83 to 114 L (22 to 30 US gal) 2.15 L (72 oz)

114 to 163 L (30 to 43 US gal) 3.00 L (100 oz)

163 to 242 L (43 to 64 US gal) 4.40 L (148 oz)

For additional information about adding an extender,consult your Caterpillar Dealer.

i02063615

Cooling System Coolant Level- CheckSMCS Code: 1350-535-FLV






Park the machine on level ground. Fully retractthe boom and fully lower the boom. Move thetransmission control to the NEUTRAL position andensure that the parking brake is engaged. Shut offthe engine.


The coolant tank for the cooling system is located inthe engine compartment.

Check the coolant level while the engine is cold. Thecoolant level should be maintained to the “FULL” lineon the coolant tank.

140 SEBU7708-08Maintenance SectionCooling System Coolant Sample (Level 1) - Obtain

i02253552

Cooling System CoolantSample (Level 1) - ObtainSMCS Code: 1395-008; 7542

Note: It is not necessary to obtain a CoolantSample (Level 1) if the cooling system is filledwith Cat ELC (Extended Life Coolant). Coolingsystems that are filled with Cat ELC should havea Coolant Sample (Level 2) that is obtained atthe recommended interval that is stated in theMaintenance Interval Schedule.

Note: Obtain a Coolant Sample (Level 1) if thecooling system is filled with any other coolantinstead of Cat ELC. This includes the followingtypes of coolants.

• Commercial long life coolants that meet theCaterpillar Engine Coolant Specification -1(Caterpillar EC-1)

• Cat Diesel Engine Antifreeze/Coolant (DEAC)

• Commercial heavy-duty coolant/antifreeze

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.

Note: Level 1 results may indicate a need forLevel 2 Analysis.


Refer to the Operation and Maintenance Manual,“Access Doors and Covers” for the location of theservice points.

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In orderto receive the full effect of S·O·S analysis, youmust establish a consistent trend of data. In orderto establish a pertinent history of data, performconsistent samplings that are evenly spaced.Supplies for collecting samples can be obtained fromyour Caterpillar dealer.

Use the following guidelines for proper sampling ofthe coolant:

• Keep the unused sampling bottles stored in plasticbags.

• Keep the lids on empty sampling bottles until youare ready to collect the sample.

• Complete the information on the label for thesampling bottle before you begin to take thesamples.

• Use a designated pump to collect the sample inorder to avoid contamination.

• Obtain coolant samples directly from the coolanttank. You should not obtain the samples from anyother location.

• Place the sample in the mailing tube immediatelyafter obtaining the sample in order to avoidcontamination.

• Never collect samples from the drain for a system.

Submit the sample for Level 1 analysis.

For additional information about coolant analysis, seeSpecial Publication, SEBU6250, “Caterpillar MachineFluids Recommendations” or consult your Caterpillardealer.

i02124459

Cooling System CoolantSample (Level 2) - ObtainSMCS Code: 1395-008; 7542

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.


Cooling System Pressure Cap - Clean/Replace


Refer to the Operation and Maintenance Manual,“Access Doors and Covers” for the location of theservice points.

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. Suppliesfor collecting samples can be obtained from yourCaterpillar dealer.

Refer to Operation and Maintenance Manual,“Cooling System Coolant Sample (Level 1) - Obtain”for the guidelines for proper sampling of the coolant.

Submit the sample for Level 2 analysis.

For additional information about coolant analysis, seeSpecial Publication, SEBU6250, “Caterpillar MachineFluids Recommendations” or consult your Caterpillardealer.

i02124461

Cooling System Pressure Cap- Clean/ReplaceSMCS Code: 1382-070; 1382-510







The cooling system pressure cap is located on thecoolant tank inside the engine compartment.

1. Remove the cap slowly in order to relieve thepressure.

2. Inspect the cap and the gasket for damage, forforeign material, and for deposits.

3. Clean the cap with a clean cloth or replace thecap if it is necessary.

Note: Always check the pressure rating of the oldcap before you replace the cap. Replace the old capwith a new cap of the same pressure rating.

142 SEBU7708-08Maintenance SectionCooling System Water Temperature Regulator - Replace

4. Reinstall the cap.

i02429544

Cooling System WaterTemperature Regulator -ReplaceSMCS Code: 1355-510; 1393-010









NOTICEFailure to replace the engine's water temperature reg-ulator on a regularly scheduled basis could cause se-vere engine damage.

NOTICESince Caterpillar engines incorporate a shunt designcooling system, it is mandatory to always operate theengine with a water temperature regulator.

Depending on load, failure to operate with a watertemperature regulator could result in either an over-heating or an overcooling condition.

Replace the water temperature regulator on a regularbasis in order to reduce the chance of unscheduleddowntime and of problems with the cooling system.The water temperature regulator should also bereplaced after the cooling system has been cleaned.

Replace the water temperature regulator while thecooling system is completely drained or while thecooling system coolant is drained to a level that isbelow the water temperature regulator housing.


1. Loosen hose clamp (1).

2. Remove hose (2) from the housing.

3. Loosen hose clamp (3).

4. Remove hose (4) from the fitting.

5. Remove bolts and washers (5).

6. Remove water temperature regulator housing (6).Remove the water temperature regulator and thegasket.

NOTICEIf the water temperature regulator is installed incor-rectly, it will cause the engine to overheat.

7. Install a new water temperature regulator and anew gasket.

8. Install water temperature regulator housing (6).


Differential Oil - Change

9. Install washers and bolts (5). Tighten the bolts.

10. Install hose (4). Tighten hose clamp (3).

11. Install hose (2). Tighten hose clamp (1).

12.Refill the cooling system. Refer to Operationand Maintenance Manual, “Capacities (Refill)”and Special Publication, SEBU6250, “CaterpillarMachine Fluids Recommendations”.

i02431047

Differential Oil - ChangeSMCS Code: 3258-044-OC





Rear Axle Differential


1. Clean the area around the plugs. Remove thefollowing plugs for the rear differential:

• Drain plug (1)

• Combined level plug and filler plug (2)

Allow the oil to drain into a suitable container.

2. Clean drain plug (1) and reinstall drain plug (1).

3. Add new oil to the differential housing throughfiller hole (2) until the oil is level with the threadsfor plug (2). Refer to Operator and MaintenanceManual, “Lubricant Viscosities” for the correctgrade of oil. Refer to Operation and MaintenanceManual, “Capacities (Refill)” and SpecialPublication, SEBU6250, “Caterpillar MachineFluids Recommendations” for more detailedlubricant information.

4. Clean combined level plug and filler plug (2).Reinstall combined level plug and filler plug (2).

Front Axle Differential


1. Clean the area around the plugs. Remove thefollowing plugs for the front differential:

• Drain plug (3)

• Combined level plug and filler plug (4)

Allow the oil to drain into a suitable container.

2. Clean drain plug (3) and reinstall drain plug (3).

3. Add new197-0017 Axle and Brake Oil Additive tothe differential housing through hole (4). Refer toOperation and Maintenance Manual, “Capacities(Refill)” for more detailed information.

144 SEBU7708-08Maintenance SectionDifferential Oil Level - Check

4. Add new oil to the differential housing through fillerhole (4) until the oil is level with the threads forplug (4). When you are filling the front axle with oilyou should allow time for the oil to drain throughthe differential into the other side of the axle.Ensure that the correct quantity of oil is added tothe axle in order to fill the differential and the axlehousing. Damage to the differential will result ifthis procedure is not observed. Refer to Operatorand Maintenance Manual, “Lubricant Viscosities”for the correct grade of oil.

Refer to Operation and Maintenance Manual,“Capacities (Refill)” and Special Publication,SEBU6250, “Caterpillar Machine FluidsRecommendations” for more detailed lubricantinformation.

5. Clean combined level plug and filler plug (4).Reinstall combined level plug and filler plug (4).

i02431134

Differential Oil Level - CheckSMCS Code: 3258-535-FLV





Rear Axle Differential


1. Clean the area around combined level and fillerplug (1) for the rear differential. Remove combinedlevel and filler plug (1) and check that the oil islevel with the hole for combined level and fillerplug (1).

2. If necessary, add oil through the same hole.

3. Clean combined level and filler plug (1) and installcombined level and filler plug (1).

Front Axle Differential


1. Clean the area around combined level andfiller plug (2) for the front differential. Removecombined level and filler plug (2) and check thatthe oil is level with the hole.

2. If necessary, add oil through the same hole.

3. Clean combined level and filler plug (2) and installcombined level and filler plug (2).


Differential Oil Sample - Obtain

i02431142

Differential Oil Sample - ObtainSMCS Code: 3258-008

Hot oil and components can cause personal in-jury.

Do not allow hot oil or components to contactskin.




g00953223Illustration 226Rear axle differential

g01054761Illustration 227Front axle differential

Fully retract the boom and fully lower the boom. Movethe transmission control to the NEUTRAL positionand ensure that the parking brake is engaged. Shutoff the engine.

Obtain an oil sample from each axle. Keep the oilsamples separate from each other.

Clean the area around combined level and filler plug(1) for the differential. Remove combined level andfiller plug (1). Use a sampling gun in the filler hole inorder to obtain an oil sample. Inspect combined leveland filler plug (1) for damage. Install combined leveland filler plug (1).

Analysis of oil from each axle will provide an accuraterepresentation of oil condition within each system.

Use S·O·S Oil Analysis in order to monitor thecondition of your oil.

For additional information, refer to SpecialPublication, SEBU6250, “Caterpillar Machine FluidsRecommendations”.

i01618061

Drive Shaft Spline - LubricateSMCS Code: 3253-086-SN

NOTICEApply lubricant to the fittings with a hand operatedgrease gun only. Use of pressure operated lubricatingequipment damages the seals.

146 SEBU7708-08Maintenance SectionDrive Shaft Universal Joint Bolts - Check

g00837541Illustration 228Location of the Drive Shafts

The following drive shafts must be lubricated:

• The front drive shaft

• The rear drive shaft

g00864761Illustration 229Typical Lubrication Point

There is a grease nipple on the slider of each driveshaft.

Lubricate the drive shaft splines through the greasenipples.

i02294864

Drive Shaft Universal JointBolts - CheckSMCS Code: 3251-535; 3253


Locations of the Universal Joints


Ensure that the bolts for the front drive shaft universaljoints and the rear drive shaft universal joints aretightened to the correct standard torque. Refer toSpecifications, SENR3130, “Torque Specifications”for the correct torque.

i02063533

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

Note: The primary air filter element can be used upto three times if the element is properly cleaned andinspected. Replace the primary air filter element ifthe element has been in service for 500 hours orsix months. This replacement should be performedregardless of the number of cleanings.


Engine Air Filter Primary Element - Clean/Replace



2. Slide out retaining clip (1).

3. Release cover (2) from air filter housing (3) byrotating counterclockwise. Remove the cover fromthe housing.

4. Remove primary element (4) from filter housing(3). To avoid dislodging any dust, take care toavoid touching the element against the sides ofthe housing. Inspect the primary element. If thepleats or the seals are damaged, discard theprimary element. Replace a damaged primaryelement with a clean primary element.

5. If the primary element is not damaged, you mayclean the primary element. Refer to Operation andMaintenance Manual, “Cleaning Primary Air FilterElements”.

6. When you clean the inside of the pleats, direct theair along the pleats. Inspect the primary elementafter you clean the primary element.

7. Clean the inside of the filter housing and cleanthe cover. Pay particular attention to the sealingsurface of the outlet tube, which fits inside theprimary element.

8. Install a clean primary element.

9. Install the cover.

10.Reset the engine air filter service indicator bypressing button (5).


11.Start the engine. If the engine air filter serviceindicator (6) illuminates on the dash panel,install a new primary element. Refer to the“Alert Indicators” section of Operation andMaintenance Manual, “Monitoring System” forfurther information. Also, if the exhaust smokeis black, install a new primary element. Replacethe engine air filter secondary element when youreplace the primary filter element. Refer to theOperation and Maintenance Manual, “Engine AirFilter Secondary Element - Replace”.

12.Close the engine enclosure.

Cleaning Primary Air FilterElements

NOTICECaterpillar recommends certified air filter cleaning ser-vices available at participating Caterpillar dealers. TheCaterpillar cleaning process uses proven proceduresto assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt toclean the filter element:

Do not tap or strike the filter element in order to re-move dust.

Do not wash the filter element.

Use low pressure compressed air in order to removethe dust from the filter element. Air pressure must notexceed 207 kPa (30 psi). Direct the air flow up thepleats and down the pleats from the inside of the filterelement. Take extreme care in order to avoid damageto the pleats.

Do not use air filters with damaged pleats, gaskets, orseals. Dirt entering the engine will cause damage toengine components.

148 SEBU7708-08Maintenance SectionEngine Air Filter Primary Element - Clean/Replace

NOTICEDo not clean the air filter elements by bumping or tap-ping. This could damage the seals. Do not use ele-ments with damaged pleats, gaskets, or seals. Dam-aged elements will allow dirt to pass through. Enginedamage could result.

Visually inspect the primary air filter element beforecleaning. Inspect the air filter element for damage tothe seal, the gaskets, and the outer cover. Discardany damaged air filter elements.

There are two common methods that are used toclean primary air filter elements:

• Pressurized air

• Vacuum cleaning

Pressurized Air

Pressurized air can be used to clean primary air filterelements that have not been cleaned more than twotimes. Pressurized air will not remove deposits ofcarbon and oil. Use filtered, dry air with a maximumpressure of 207 kPa (30 psi).


Note: When the primary air filter elements arecleaned, always begin with the clean side (inside)in order to force dirt particles toward the dirty side(outside).

Aim the hose so that the air flows inside the elementalong the length of the filter in order to help preventdamage to the paper pleats. Do not aim the stream ofair directly at the primary air filter element. Dirt couldbe forced further into the pleats.

Vacuum Cleaning

Vacuum cleaning is another method for cleaningprimary air filter elements which require daily cleaningbecause of a dry, dusty environment. Cleaning withpressurized air is recommended prior to vacuumcleaning. Vacuum cleaning will not remove depositsof carbon and oil.

Inspecting the Primary Air FilterElements


Inspect the clean, dry primary air filter element. Usea 60 watt blue light in a dark room or in a similarfacility. Place the blue light in the primary air filterelement. Rotate the primary air filter element. Inspectthe primary air filter element for tears and/or holes.Inspect the primary air filter element for light that mayshow through the filter material. If it is necessary inorder to confirm the result, compare the primary airfilter element to a new primary air filter element thathas the same part number.

Do not use a primary air filter element that has anytears and/or holes in the filter material. Do not usea primary air filter element with damaged pleats,gaskets or seals. Discard damaged primary air filterelements.

Storing Primary Air Filter Elements

If a primary air filter element that passes inspectionwill not be used, the primary air filter element canbe stored for future use.


Engine Air Filter Primary Element - Replace


Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. An airflow restrictionmay result. To protect against dirt and damage, wrapthe primary air filter elements in Volatile CorrosionInhibited (VCI) paper.

Place the primary air filter element into a box forstorage. For identification, mark the outside of thebox and mark the primary air filter element. Includethe following information:

• Date of cleaning

• Number of cleanings

Store the box in a dry location.

i02124504

Engine Air Filter PrimaryElement - ReplaceSMCS Code: 1054-510-PY

NOTICEThe filter should be kept in service no longer than sixmonths or 500 service hours.

Refer to Operation and Maintenance Manual, “EngineAir Filter Primary Element - Clean/Replace” for thereplacement procedure.

Write the date on the element, when the element isreplaced.

i02063553

Engine Air Filter SecondaryElement - ReplaceSMCS Code: 1054-510-SE

NOTICEAlways replace the secondary filter element. Neverattempt to reuse the element by cleaning.

The secondary filter element should be replaced at thetime the primary element is serviced for the third time.



2. Slide out retaining clip (1).

3. Release cover (2) from air filter housing (3) byrotating counterclockwise. Remove the cover fromthe housing.

4. Remove primary element (4) from filter housing(3). To avoid dislodging any dust, take care toavoid touching the element against the sides ofthe housing.

5. Remove secondary filter element (5).

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

7. Uncover the air inlet opening. Install a newsecondary element.

8. Install the primary element and the air filter cover.


150 SEBU7708-08Maintenance SectionEngine Mounts - Inspect

i01875966

Engine Mounts - InspectSMCS Code: 1152-040

Check the engine mounts for deterioration. Checkthe bolts on the engine mounts for the proper torque.The correct torque on the bolts will prevent excessiveengine vibration that is caused from impropermounting.

i02124465

Engine Oil Level - CheckSMCS Code: 1000-535-FLV

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact skin.

NOTICEDo not under fill or overfill engine crankcase with oil.Either condition can cause engine damage.

Park the machine on level ground.

Check the crankcase oil level with the machine level.If the machine has just been stopped, wait for aminimum of one minute. The minute will allow oil todrain back into the crankcase.


1. Open the engine enclosure. The oil level dipstickis located on the front of the engine.

2. Maintain the oil level between the “ADD” mark andthe “FULL” mark on the dipstick.

Note: When you operate the machine on severeslopes, the oil level in the engine crankcase must beat the “FULL” mark on the dipstick.


3. Clean the oil filler cap. Remove the oil filler cap. Ifnecessary, add oil.

4. Install the oil filler cap.


i02294933

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

Park the machine on level ground. Fully retract andfully lower the boom. Move the transmission controlto the NEUTRAL position and ensure that the parkingbrake is engaged.


Obtain an engine oil sample while the engine isrunning. The sampling valve for the engine oil islocated in the engine compartment on the filter headfor the engine oil filter.


Engine Oil and Filter - Change

Refer to Special Publication, SEBU6250, “CaterpillarMachine Fluids Recommendations”, “S·O·S OilAnalysis” for information that pertains to obtaining asample of the engine oil. Refer to Special Publication,PEHP6001, “How To Take A Good Oil Sample” formore information about obtaining a sample of theengine oil.

i02429550

Engine Oil and Filter - ChangeSMCS Code: 1318-510





Note: Change the engine oil and the filter after every500 hours. This is the normal interval provided thatthe following conditions are met:

• Only genuine Caterpillar filters must be used.

• Only Caterpillar Multigrade Diesel Engine Oil(DEO) to specification CG-4 or an equivalent mustbe used. Refer to Operation and MaintenanceManual, “Lubricant Viscosities” and SpecialPublication, SEBU6250, “Caterpillar MachineFluids Recommendations” for more detailedlubricant information.

• Working conditions must be clean and applicationsmust be light. Obtain an S·O·S oil sample at thefirst 250 hours in order to determine if the oilchange interval can be decreased.

• The sulfur content of the fuel must be between0.05% to 0.5%. If a higher percentage of sulfur ispresent in the fuel, the engine oil and the filter willneed to be changed more often. 0.5% to 1.0% ofsulfur content will require the engine oil and thefilter to be changed after every 250 hours. 1.0% to1.5% of sulfur content will require the engine oiland the filter to be changed after every 125 hours.

1. Before you drain the engine oil, park the machineon a level surface and engage the parking brake.The engine oil should be warm before you drainthe oil. Stop the engine.

2. Open the engine access door.


3. Position the end of hose (3) into a suitablecontainer. Turn shutoff valve (2) counterclockwisein order to drain the engine oil from the crankcase.Turn the shutoff valve clockwise in order to closethe shutoff valve. Allow the oil to drain from thehose.

4. Remove old engine oil filter (1) with a filter wrench.

5. Clean the filter housing base. Ensure that all ofthe old seal is removed.

6. Apply a thin film of clean engine oil to the seal ofthe new engine oil filter.

7. Install new engine oil filter (1) hand tight until theseal of engine oil filter (1) contacts the base. Notethe position of the index marks on the filter inrelation to a fixed point on the filter base.

152 SEBU7708-08Maintenance SectionEngine Valve Lash - Check

Note: There are rotation index marks on engine oilfilter (1) that are spaced 90 degrees or 1/4 of a turnaway from each other. When you tighten engine oilfilter (1), use the rotation index marks as a guide.

8. Tighten the filter according to the instructions thatare printed on the filter. Use the index marks asa guide. For non-Caterpillar filters, refer to theinstallation instructions that are provided by thesupplier of the filter.

Note: You may need to use a Caterpillar strapwrench, or another suitable tool, in order to turnthe filter to the amount that is required for finalinstallation. Make sure that the installation tool doesnot damage the filter.


9. Remove filler cap (4) and fill the crankcase withnew oil.

Refer to Operation and Maintenance Manual,“Lubricant Viscosities” for more information on thetype of oil that is required. Refer to Operation andMaintenance Manual, “Capacities (Refill)” for moreinformation on the quantity of oil that is required.

10.Check that the parking brake is engaged and thatthe transmission is in NEUTRAL and then startthe engine. Operate the engine for five minutes atlow idle. Inspect the engine for leaks and makeany repairs that are necessary.

11.Stop the engine. Wait for two minutes after youstop the engine. Stopping the engine allows oilto drain back to the crankcase. Check the oillevel. If necessary, add oil. Maintain the oil levelbetween the “ADD” mark and the “FULL” mark onthe dipstick. Install the filler cap.

12.Close the engine access door.

i02218773

Engine Valve Lash - CheckSMCS Code: 1105-535

Maintenance is recommended by Caterpillar forengine valve lash adjustments. The maintenance forthe engine valve lash is part of the lubrication andpreventive maintenance schedule in order to providemaximum engine life.

Note: The engine valve lash should be checked atevery 2000 hours or 2 years.

NOTICEOnly qualified service personnel should perform thismaintenance. Refer to the Service Manual or yourCaterpillar Dealer for the complete engine valve lashadjustment procedure.

Be sure the engine cannot be started while thismaintenance is being performed. To prevent pos-sible injury, do not use the starting motor to turnthe flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring/adjusting engine valve lash clearance.

NOTICEOperation of Caterpillar Engines with improper enginevalve lash adjustments will reduce the engine efficien-cy. This reduced efficiency could result in excessivefuel usage and/or shortened engine component life.

Measure the engine valve lash with the enginestopped. To obtain an accurate measurement, allowat least 20 minutes for the valves to cool to enginecylinder head and block temperature.


Final Drive Oil - Change

i02429551

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




g00952214Illustration 243Position of the plug for draining the oil

1. Park the machine on level ground. Positionthe drain plug in the position that is shown inIllustration 243.

2. Fully retract the boom and fully lower the boom.Move the transmission control to the NEUTRALposition and engage the parking brake. Shut offthe engine.

3. Clean the area around the drain plug. Removethe drain plug and drain the oil into a suitablecontainer.

g00952220Illustration 244Position of the plug for filling the oil

4. Move the machine until the plug hole is at thehorizontal center line of the wheel. The correctposition is shown in Illustration 244.

5. Add oil to the final drive through the plug hole.Oil should be dripping out of the plug hole whenthe final drive is full of oil. Refer to Operation andMaintenance Manual, “Capacities (Refill)” andOperation and Maintenance Manual, “LubricantViscosities” for more information.

Refer to Special Publication, SEBU6250,“Caterpillar Machine Fluids Recommendations”for more detailed lubricant information.

6. Clean the drain plug and reinstall the drain plug.

7. Repeat the steps that are explained above foreach of the three remaining final drives.

i02429552

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




154 SEBU7708-08Maintenance SectionFinal Drive Oil Sample - Obtain


1. To check the oil level on the final drive, positionthe machine on level ground. Position the plugfor the final drive on the horizontal center line ofthe wheel.

2. Fully retract the boom and fully lower the boom.Move the transmission control to the NEUTRALposition and engage the parking brake. Shut offthe engine.

3. Clean the area around the plug. Remove the plug.

4. Check that the oil is level with the plug hole. Ifnecessary, add oil through the plug hole.

5. Clean the plug and reinstall the plug.

6. Repeat Step 1 through Step 5 for each of the threeremaining final drives.

i02429554

Final Drive Oil Sample - ObtainSMCS Code: 4050-008

Hot oil and components can cause personal in-jury.

Do not allow hot oil or components to contactskin.





Fully retract the boom and fully lower the boom. Movethe transmission control to the NEUTRAL positionand engage the parking brake. Shut off the engine.

Obtain a sample of oil from each final drive. Keep theoil samples separate from each other.

Select a final drive in order to obtain a sample of oil.Park the machine on level ground and position theplug for the final drive on the horizontal center lineof the wheel.

Clean the area around the plug and remove the plug.Use a sampling gun in the plug hole in order to obtainan oil sample from the final drive. Inspect the plug fordamage. Install the plug.

Repeat this procedure for the remaining final drives.Analysis of oil from the corresponding final drive willprovide an accurate representation of oil conditionwithin each system.

Use S·O·S Oil Analysis in order to monitor thecondition of your oil.

For additional information, refer to SpecialPublication, SEBU6250, “Caterpillar Machine FluidsRecommendations”.


Fork Leveling Cylinder Pin - Lubricate

i01865222

Fork Leveling Cylinder Pin -LubricateSMCS Code: 5823-086-PN


Lubricate the pin for the fork leveling cylinder throughthe fitting.

i01946923

Frame Leveling Cylinder Pin -LubricateSMCS Code: 7078-086-PN

S/N: SLC1-Up

g00856617Illustration 248Location of the frame leveling cylinder


The frame leveling cylinder is located at the frontright of the machine.

Lubricate the frame leveling cylinder pin through thefitting on the top mounting point.

i02298174

Fuel System - PrimeSMCS Code: 1250-548

1. Turn the engine start switch to the ON position.Leave the switch in the ON position for 3 minutes.

NOTICEDo not crank the engine for more than 30 seconds.Allow the starting motor to cool for two minutes beforecranking again.

Turbocharger (if equipped) damage can result, if theengine rpm is not kept low until the engine oil light/gauge verifies the oil pressure is sufficient.

2. Start the engine. Allow the engine to operate atlow idle until the engine runs smoothly.

Note: If additional priming is necessary, referto Systems Operation, Testing and Adjusting,RENR2410, “3054E Engine for Caterpillar BuiltMachines”, “Fuel System - Prime” for additionalinformation.

156 SEBU7708-08Maintenance SectionFuel System Water Separator - Drain

i02429561

Fuel System Water Separator- DrainSMCS Code: 1263-543

Personal injury or death may result from failure toadhere 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 smokewhile working on the fuel system.

Turn the disconnect switch OFF or disconnect thebattery when changing fuel filters.




1. Park the machine on level ground. Fully retractand fully lower the boom. Move the transmissioncontrol to the NEUTRAL position and ensure thatthe parking brake is engaged. Shut off the engine.



3. Loosen the valve and drain the water andsediment into a suitable container.

4. Tighten the valve.

i02409774

Fuel Tank Cap - CleanSMCS Code: 1273-070-Z2


The fuel filler cap is located behind protection cover(3) on the left side of the cab.

Note: Before the machine is refueled or before thefuel filler cap is cleaned, remove foreign material fromthe top of the fuel tank.

1. In order to open protection cover (3), unlock lock(2) and turn lock (4) counterclockwise. Then, pulllatch (1) outward.


Fuel Tank Water and Sediment - Drain

g01204058Illustration 252Fuel filler cap

SLA1-UPSLB1-UPSLC1-699

g01204075Illustration 253Fuel filler cap

SLC700-UP

2. Locate fuel filler cap (6) and remove the padlock,if equipped.

3. Lift latch (5) and turn the fuel filler capcounterclockwise. This will release the fuel fillercap.

4. Remove fuel filler cap (6) and inspect the fuel fillercap. Replace the fuel filler cap if the fuel filler capis damaged.

5. Install the fuel filler cap.

6. Install the padlock, if equipped.

7. Close the protection cover.

i02429572

Fuel Tank Water and Sediment- DrainSMCS Code: 1273-543-M&S

Personal injury or death may result from failure toadhere 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 smokewhile working on the fuel system.

Turn the disconnect switch OFF or disconnect thebattery when changing fuel filters.





The fuel tank drain plug is located on the bottom ofthe fuel tank.

158 SEBU7708-08Maintenance SectionFuses and Relays - Replace

1. Loosen the fuel tank drain plug. Do not removethe fuel tank drain plug. Allow the water and thesediment to drain into a suitable container andthen tighten the fuel tank drain plug.

2. Add fuel to the fuel tank. Fill the fuel tank at theend of each day of operation. Filling the fuel tankafter every day of operation will drive out moistair. Also, filling the fuel tank helps to minimizecondensation. Do not fill the fuel tank to the top.Warm fuel expands and the fuel may overflow ifthe fuel tank is overfilled.

Note: Never allow the fuel tank to run dry.

i02062538

Fuses and Relays - ReplaceSMCS Code: 1417-510; 4493-510

g00951206Illustration 255Fuse panel

The fuse panel is located behind an access coverin the left side of the cab arrangement. Remove thecover in order to expose the fuses and relays.

Fuses

NOTICEReplace fuses with the same type and size only. Oth-erwise, electrical damage can result.

If it is necessary to replace fuses frequently, an electri-cal problemmay exist. Contact your Caterpillar dealer.

The fuses protect the electrical system from damagethat is caused by overloaded circuits. If the elementinside the fuse separates, replace the fuse. Checkthe circuit if the element is separated in the new fuse.Repair the circuit, if necessary.

Note: Your machine may not utilize all of the fusesthat are listed here. You should only replace thesefuses with fuses of the same type and current rating.

Use the fuse puller in order to remove the fuses. Thefuse puller is located to the left of the fuse panel.


Illustration 256 shows the location of the fuses. Thefuses are numbered from the top to the bottom.


Film on fuse access cover

A film with the positions of the fuses is located on theinside of the access cover. The location of the fusematches the location of the pictograph on the film.


Fuses and Relays - Replace

Frame Level (1) – 10 AMP

Differential Lock (2) – 10 AMP

Front Window Wiper (3) – 10 AMP

Rear Window Wiper (4) – 15 AMP

High Speed Air Conditioner Blower (5) –25 AMP

Low Speed Air Conditioner Blower (6) –15 AMP

Hydraulic Auxiliary Circuit (7) – 10 AMP

Steering Alignment (8) – 10 AMP

Joystick Control (9) – 10 AMP

Spare Position (10)

Access Platform (11) – 10 AMP

PHS Circuit (12) – 15 AMP

Turn Signals (13) – 10 AMP

Work Light (14) – 10 AMP

Work Light (15) – 10 AMP

Rear Work Lights (16) – 10 AMP

Engine Start (17) – 10 AMP

Hazard Flashers (18) – 10 AMP

Left Side Parking Light, Left Side RearLight, and License Plate Light (19) – 15AMP

Right Side Parking Light, Right SideRear Light, and Fog Light (20) – 15 AMP

Rotating Beacon (21) – 10 AMP

Alternator Indicator Light and OilPressure Indicator Light (22) – 15 AMP

Seat Height Adjustment (23) – 10 AMP

Radio which is Independent of EngineStart Switch (24) – 10 AMP

LH Tail Lights (25) – 10 AMP

RH Tail Lights (26) – 10 AMP

Engine Run (27) – 10 AMP

Fuel Pump (28) – This fuse is not usedon this machine.

160 SEBU7708-08Maintenance SectionFuses and Relays - Replace

Radio which is dependent of EngineStart Switch (29) – 10 AMP

Horn (30) – 10 AMP

Electrical Monitoring System (31) – 15AMP

Electrical Monitoring System (32) – 20AMP


For Tier II machines, the fuse for the fuel pump islocated in the engine compartment next to the circuitbreakers. Remove the protective cover in order toaccess the fuse.

RelaysNote: Your machine may not utilize all of the relaysthat are listed here. You should only replace theserelays with relays of the same type.


Illustration 259 shows the location of the relays onthe fuse panel. A pictograph is located on the accesscover. The location of the relay matches the locationof the pictograph on the film.

Fuel Pump (33)

Ground for Quick Coupler (34)

Power for Quick Coupler (35)

Crab Steering (36)

Reverse Backup Lights (37)

Circle Steer (38)

Frame Level (39)

Ground for Auxiliary Diverter Valve (40)

Power for Auxiliary Diverter Valve (41)

Differential Lock (42)

Fuel Pump (43)

Engine Solenoid (44)


Indicators and Gauges - Test

i01111203

Indicators and Gauges - TestSMCS Code: 7450-081

Check for broken indicator lights, broken switches orbroken lenses on the instrument panel gauges.

Start the engine. Run the engine until the instrumentpanel gauges have stabilized. Check that theinstrument panel gauges are operating correctly.

Stop the engine and perform any necessary repairsbefore the machine is operated.

i02084254

Longitudinal Stability Indicator- CalibrateSMCS Code: 7856-524

The use of a defective longitudinal stability indi-cator (LSI) could lead to the instability of the ma-chine. Do not operate the machine if the LSI is notfully serviceable. The instability of the machinecould cause personal injury or death.

Refer to System Operation, Testing and Adjusting,RENR5196, “TH220B, TH330B, TH340B,TH350B, TH360B, TH460B, TH560B and TH580BTelehandlers Longitudinal Stability Indicator System”,“Calibration” for information on this procedure.

i02036900

Longitudinal Stability Indicator- TestSMCS Code: 7856-081

The following procedure must be followed when youtest the operation of the longitudinal stability indicatorsystem.

Initial Test1. Perform the following procedures to the machine:

a. Remove any work tool from the machine.Remove any load that is applied to the rearhitch.

b. Position the machine on level ground. Ifnecessary, level the frame of the machine.

c. Ensure that all the wheels are facing straightahead. Drive the machine forward and drivethe machine in reverse for 3 m (10 ft).

d. For both the TH220B and the TH330B, tilt thecoupler fully backward. On the TH340B, tilt thecoupler fully forward.

e. Fully lower and retract the boom.

f. Engage the parking brake and move thetransmission control to the NEUTRAL position.

2. Turn the ignition to the OFF position. Wait for 30seconds.

3. Turn the ignition to the ON position, but do notcrank the engine.

Note: The machine will perform the self test. Referto the “Engine Start Switch” topic in Operation andMaintenance Manual, “Operator Controls” for moreinformation.

4. After the self tests are completed, the machine willtest the longitudinal stability indicator system.

a. If the test is successful, the gauge willfunction in the manner that was describedin the Operation and Maintenance Manual,“Monitoring System”. This indicates that thesystem is operating correctly.

b. The needle of the longitudinal stability indicatorwill move into the red zone of the gauge if thetest is failed. An intermittent audible alarm willsound. The warning light will be activated. Turnthe ignition to the OFF position in order to stopthe alarm.

Note: This test is performed automatically. The testwill be conducted when the ignition is switched fromthe OFF position to the ON position.

Second TestPerform the following test if the machine fails theinitial test of the longitudinal stability indicator.

1. Ensure that all of the steps have been performedin Step 1 of “Initial Test”.

2. Repeat the test of longitudinal stability indicatorsystem.

Note: If the machine continues to fail system testsof the longitudinal stability indicator, the machinemust not be operated. Call your Caterpillar dealerfor recalibration of the longitudinal stability indicatorsystem.

162 SEBU7708-08Maintenance SectionOil Filter - Inspect

i02106227

Oil Filter - InspectSMCS Code: 1308-507; 3067-507; 5068-507

Inspect a Used Filter for Debris


The element is shown with debris.

Use a filter cutter to cut the filter element open.Spread apart the pleats and inspect the element formetal and for other debris. An excessive amount ofdebris in the filter element can indicate a possiblefailure.

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.

i02016689

Parking Brake - AdjustSMCS Code: 4267-025

If the machine moves during the “Parking Brake”test in Operation and Maintenance Manual, “BrakingSystem - Test”, perform the following procedure inorder to adjust the parking brake.

1. Apply the service brakes.


2. Disengage the parking brake.

3. As you view the parking brake handle from thefront of the machine and look toward the rear ofthe machine, turn the handle clockwise for onehalf of a turn.

4. Repeat the “Parking Brake” test procedure inOperation and Maintenance Manual, “BrakingSystem - Test”.

If the machine moves during the parking brake test,then perform the adjustment procedure again. If yourun out of adjustment on the parking brake handle,refer to Systems Operation, Testing and Adjusting,RENR5190, “Parking Brake Control - Check andAdjust”.


Pulley for Boom Extension Chain - Lubricate

i01865284

Pulley for Boom ExtensionChain - LubricateSMCS Code: 5917-086-PP

S/N: SLC1-Up


Lubricate the pulley for the boom extension chainthrough one fitting.

i01865285

Pulley for Boom RetractionChain - LubricateSMCS Code: 5917-086-PP

S/N: SLC1-Up



Fully raise the boom and lubricate the boom retractionchain roller through one fitting. Access is through ahole on the left side of the boom.

i01947023

Radiator Core - CleanSMCS Code: 1353-070-KO

If your machine is not equipped with an airconditioning system, use compressed air in order toremove dust and other debris from the radiator core.

If your machine is equipped with an air conditioningsystem, the condenser must be tilted away from theradiator in order to properly clean the radiator coreand the condenser core.

1. Open the engine access door.


164 SEBU7708-08Maintenance SectionRefrigerant Dryer - Replace

2. Open the latch that is located on top of thecondenser.


3. Tilt the condenser away from the radiator.

4. Use compressed air to remove dust and otherdebris from the radiator core and the condensercore.

5. Tilt back the condenser and fasten the latch.

Refer to Special Publication, SEBD0518, “KnowYour Cooling System” for the complete procedure forcleaning the radiator core.

i02430986

Refrigerant Dryer - ReplaceSMCS Code: 7322-710

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.


The refrigerant accumulator is located at the rear ofthe engine compartment.


Rollover Protective Structure (ROPS) and Falling Object Protective Structure (FOPS) - Inspect

Refer to Service Manual, SENR5664, “AirConditioning and Heating R-134a for All CaterpillarMachines”, “Refrigerant Accumulator - Removeand Install” for the replacement procedure of theaccumulator.

Note:When you operate the machine in a climate withhigh humidity, replace the refrigerant accumulatorafter every 1000 service hours or 6 months.

i01865289

Rollover Protective Structure(ROPS) and Falling ObjectProtective Structure (FOPS) -InspectSMCS Code: 7325-040



The front bolts (1) are located underneath the leftside of the cab.

The rear bolts (3) are located underneath thewindshield washer reservoir behind the cab.

1. Remove the bolts (2) in order to remove thewindshield washer reservoir.

2. If the bolts are damaged or missing replace thebolts with original equipment parts only. Torquethe bolts to 450 N·m (332 lb ft).

Note: Apply oil to the bolts before you install the bolts.Failure to apply oil can result in improper bolt torque.

3. Install the windshield washer reservoir, and installthe two bolts.

4. Run the machine on a rough surface. Replacethe ROPS/FOPS mounting supports if theROPS/FOPS structure makes a noise or if theROPS/FOPS structure rattles.

Do not attempt to straighten or repair theROPS/FOPS structure. If there are any cracks inthe welds, in the castings, or in any metal section ofthe ROPS/FOPS structure, consult your Caterpillardealer for repairs.

166 SEBU7708-08Maintenance SectionSeat Belt - Inspect

i02429589

Seat Belt - InspectSMCS Code: 7327-040

Always check the condition of the seat belt and thecondition of the seat belt mounting hardware beforeyou operate the machine. Replace any parts that aredamaged or worn before you operate the machine.

g00932801Illustration 270Typical example

Check the seat belt mounting hardware (1) for wearor for damage. Replace any mounting hardware thatis worn or damaged. Make sure that the mountingbolts are tight.

Check buckle (2) for wear or for damage. If the buckleis worn or damaged, replace the seat belt.

Inspect the seat belt (3) for webbing that is worn orfrayed. Replace the seat belt if the seat belt is wornor frayed.

Consult your Caterpillar dealer for the replacement ofthe seat belt and the mounting hardware.

Note:Within three years of the date of installation orwithin five years of the date of manufacture, replacethe seat belt. Replace the seat belt at the date whichoccurs first. A date label for determining the age ofthe seat belt is attached to the seat belt, the seat beltbuckle, and the seat belt retractor.

If your machine is equipped with a seat beltextension, also perform this inspection procedure forthe seat belt extension.

i02429594

Seat Belt - ReplaceSMCS Code: 7327-510

Within three years of the date of installation or withinfive years of the date of manufacture, replace theseat belt . Replace the seat belt at the date whichoccurs first. A date label for determining the age ofthe seat belt is attached to the seat belt, the seat beltbuckle, and the seat belt retractor.

g01152685Illustration 271(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 ofthe seat belt and the mounting hardware.

If your machine is equipped with a seat beltextension, also perform this replacement procedurefor the seat belt extension.

SEBU7708-08 167Maintenance SectionTire Inflation - Check

i01638972

Tire Inflation - CheckSMCS Code: 4203-535-AI

Personal injury can result from improper tire infla-tion.

A tire blowout or rim failure can result from im-proper or misused equipment.

Use a self-inflating chuck and stand behind thetread when inflating a tire.

Proper inflating equipment, and training in usingthe equipment, are necessary to avoid overinflat-ing.

Before inflating tire, put the tire in a restrainingdevice.

Some machines are equipped with tires that are filledwith air. Other machines are equipped with tires thatare filled with foam. Pressures of tires that are filledwith air must be checked. Pressures of tires that arefilled with foam do not require checking.

1. Park the machine on level ground. Apply theparking brake. Retract and lower the boom. Shutoff the engine.

2. Clean the area around the valve stem.

3. Remove the dust cover for the valve stem.

4. Stand behind the tire tread and use a Caterpillar4S-6524 Pressure Gauge, or 1P-0545 PressureGauge to check the tire pressure. If these pressuregauges are not available use an equivalent toolto check the tire pressure. Add air if the pressureis low.

5. Install the dust cover on the valve stem.

Refer to the following additional information abouttire inflation:

• Operation and Maintenance Manual, “Tire ShippingPressure”

• Operation and Maintenance Manual, “Tire InflationPressure Adjustment”

Consult your Caterpillar Dealer for further informationon the correct operating pressures and the correctload ratings.

i02413115

Transmission and HydraulicSystem Oil - ChangeSMCS Code: 3080-044; 5056-044







168 SEBU7708-08Maintenance SectionTransmission and Hydraulic System Oil - Change

g01205579Illustration 273Hydraulic tank filler cap

SLA1-UPSLB1-UPSLC1-699

g01205670Illustration 274Hydraulic tank filler cap

SLC700-UP

2. Lift latch (5). Turn the latch counterclockwisein order to relieve the pressure in the hydraulicsystem. Remove hydraulic tank filler cap (6).


3. Remove drain plug (7) from the bottom of thehydraulic tank and drain the oil into a suitablecontainer. Clean the drain plug. Install the drainplug back into the hydraulic tank.


4. Remove drain plug (8) from the bottom of thetransmission and drain the oil into a suitablecontainer. Clean the drain plug. Install the drainplug back into the transmission.

5. Fill the hydraulic tank with new Caterpillar TDTOoil and install the hydraulic tank filler cap. Cleanup any oil that has spilled. Refer to Operation andMaintenance Manual, “Lubricant Viscosities” andOperation and Maintenance Manual, “Capacities(Refill)” for additional information.

Note: Do not start the engine until the hydraulictank is filled with new oil. Starting the engine beforerefilling with oil may damage the scavenge pump orthe transmission.

6. Start the engine. Check for clearance for theboom. The boom will need clearance for fullextension. You need enough clearance to fullyraise the boom and you need enough clearance tolower the boom. Raise and lower the boom severaltimes. Extend and retract the boom several times.


Transmission and Hydraulic System Oil Filter - Replace

7. With the boom in the travel position, drive themachine slowly forward. Steer the machine fromthe left to the right.

8. Park the machine and check the oil level. Ifnecessary, add oil.


Reference: Refer to Operation and MaintenanceManual, “Transmission and Hydraulic System OilLevel - Check” for additional information.

i02413142

Transmission and HydraulicSystem Oil Filter - ReplaceSMCS Code: 3067-510; 5068-510








Hydraulic tank filler capSLA1-UPSLB1-UP

SLC1-699

170 SEBU7708-08Maintenance SectionTransmission and Hydraulic System Oil Level - Check

g01205670Illustration 279Hydraulic tank filler capSLC700-UP

2. Lift latch (5), and turn the latch counterclockwisein order to relieve the pressure in the hydraulicsystem. Remove hydraulic tank filler cap (6).



4. Remove oil filter (7). After you remove the oil filter,discard the oil filter. The oil filter will contain oil.

5. Clean the housing base for the oil filter. Make surethat all of the old filter seal has been removed.

6. Apply a thin film of oil to the seal of the new oilfilter.

7. Install the new oil filter hand tight until the seal ofthe oil filter contacts the base. Note the position ofthe index marks on the filter in relation to a fixedpoint on the filter base.

Note: There are rotation index marks on the oil filterthat are spaced 90 degrees or 1/4 of a turn awayfrom each other. When you tighten the oil filter, usethe rotation index marks as a guide.

8. Tighten the oil filter according to the instructionsthat are printed on the filter. Use the index marksas a guide. For non-Caterpillar filters, refer to theinstallation instructions that are provided by thesupplier of the filter.

Note: You may need to use a Caterpillar strapwrench, or another suitable tool, in order to turnthe filter to the amount that is required for finalinstallation. Make sure that the installation tool doesnot damage the filter.

Reference: Refer to Operation and MaintenanceManual, “Transmission and Hydraulic System OilLevel - Check” for additional information.

9. Tighten hydraulic tank filler cap (6).

10.Close the protection cover.

i02413166

Transmission and HydraulicSystem Oil Level - CheckSMCS Code: 3080-535-FLV; 5056-535-FLV

Before you check the level of the hydraulic oil,perform the following procedures:

• Park the machine on a level surface.

• Retract the boom.

• Lower the work tool to the ground.



Transmission and Hydraulic System Oil Sample - Obtain

An oil level gauge is located behind protection cover(3) on the left side of the machine. In order to openthe protection cover, unlock lock (2) and turn lock (4)counterclockwise. Then, pull latch (1) outward.


Hydraulic tank filler capSLA1-UPSLB1-UP

SLC1-699


Hydraulic tank filler capSLC700-UP

Note: Run the machine for at least five minutes inorder to pressurize the hydraulic system.

You should look at oil level gauge (5) in order to checkthe level of oil in the hydraulic system. The oil levelof the hydraulic system is correct when the oil levelhas reached the line that is marked “MAX” or if the oillevel is halfway between the red line and the blue lineon the oil level gauge. If necessary, add CaterpillarTDTO to the correct oil level by the following method:

1. Lift latch (6), and loosen hydraulic tank filler cap(7) slowly in order to relieve the pressure in thehydraulic system. Remove the hydraulic tank fillercap.

2. Top up the hydraulic oil to the required leveland install the hydraulic tank filler cap. Clean upany oil that has spilled. Refer to Operation andMaintenance Manual, “Lubricant Viscosities” andOperation and Maintenance Manual, “Capacities(Refill)” for additional information.


i01946964

Transmission and HydraulicSystem Oil Sample - ObtainSMCS Code: 3030-008; 5056-008; 7542-008


The sampling valve for the transmission and hydraulicsystem oil is located in the engine compartment onthe filter base for the transmission and hydraulicsystem oil filter.

Refer to Special Publication, SEBU6250, “CaterpillarMachine Fluids Recommendations”, “S·O·S OilAnalysis” for information that pertains to obtaininga sample of the hydraulic oil. Refer to SpecialPublication, PEHP6001, “How To Take A Good OilSample” for more information about obtaining asample of the hydraulic oil.

172 SEBU7708-08Maintenance SectionTransmission and Hydraulic System Tank Breather - Clean

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Transmission and HydraulicSystem Tank Breather - CleanSMCS Code: 5056-070-BRE

S/N: SLA1-Up

S/N: SLB1-Up

S/N: SLC1-699

The breather for the transmission and hydraulicsystem tank is located directly underneath thewindshield washer reservoir.


1. Remove two bolts (1) from the top of windshieldwasher reservoir. Lift the windshield washerreservoir in order to access breather (2).


2. Loosen hose clamps (3) and remove the hosesfrom the breather.

3. Loosen bolt (4) and remove the breather.

4. Wash the breather in clean nonflammable solvent.

5. Install the clean breather, and reattach the twohoses. Tighten the two hose clamps.

6. Install the windshield washer reservoir, and installthe two bolts.

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Transmission and HydraulicSystem Tank Breather - CleanSMCS Code: 5056-070-BRE

S/N: SLC700-Up

The breather for the transmission and hydraulicsystem tank is located underneath the tank. Thebreather is located between the fuel tank and thechassis.


The fuel tank and the cradle have been removed for viewingpurposes.

1. Loosen hose clamp (1) and remove breather (2).

2. Wash the breather in clean nonflammable solvent.

3. Install the clean breather, and reattach the hose.Tighten the hose clamp.

i01630406

Turbocharger - InspectSMCS Code: 1052-040

If the turbocharger fails during engine operation,severe damage to the turbocharger compressorwheel and to the entire engine can result.


Wheel Nut Torque - Check

Turbocharger bearing failures can cause largequantities of oil to enter the intake system and theexhaust system. Loss of engine oil can result inserious engine damage.

Do not continue to operate the engine when aturbocharger bearing failure is accompanied bya significant loss of engine performance. Enginesmoke and speeding up of the engine with no loadare characteristics of a loss of engine performance.

Reference: For more information about inspectingthe turbocharger, refer to the appropriate ServiceManual for your machine's engine.

i01924132

Wheel Nut Torque - CheckSMCS Code: 4210-535

Check the wheel nut torque on new wheels and onrepaired wheels after every ten service hours untilthe specified torque is maintained.

Tighten the wheel nuts to a torque of 460 ± 60 N·m(340 ± 45 lb ft). When you install new wheels orrepaired wheels, apply one drop of lubricating oil tothe threads before you install the wheel nuts and thewashers.

i01865293

Window Washer Reservoir -FillSMCS Code: 7306-544-KE

NOTICEUse Caterpillar nonfreezing window washer solventor a commercially available windshield washer fluidin order to prevent freezing of the windshield washersystem.



1. Remove the filler cap.

2. Fill the tank with the appropriate window washersolvent.

3. Install the filler cap.

i01258249

Window Wiper -Inspect/ReplaceSMCS Code: 7305-040; 7305-510

Inspect the condition of the wiper blades. Replacethe wiper blades if the wiper blades are worn ordamaged or if streaking occurs.

i01630407

Windows - CleanSMCS Code: 7310-070; 7340


Use commercially available window cleaningsolutions to clean the windows. Stand on the groundin order to clean the outside windows, unlesshandholds are available.

174 SEBU7708-08Maintenance SectionWork Tool - Inspect/Replace

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Work Tool - Inspect/ReplaceSMCS Code: 6700-040; 6700-510

In order to help minimize unexpected, costly repairsand downtime, inspections need to be carried out ona regular basis. The interval between the inspectionsdepends on the age of the work tool and the severityof the operating conditions.

More frequent inspections will be required of olderwork tools and work tools that are used in particularlysevere operating conditions.

To perform a proper inspection, the work tool must bethoroughly cleaned. It is impossible to inspect thework tool properly if the work tool is dirty.

Early detection and repair of faults will ensurecontinued operation of the work tool. Also, earlydetection and repair will improve the availability ofthe work tool. Repair of faults will also reduce therisk of accidents.

The work tool should only be repaired by aqualified Caterpillar dealer in accordance with themanufacturers recommendations. However, if youdecide to carry out your own repairs, consult yourCaterpillar dealer for the recommended repairtechniques.

Inspect the work tool before the work tool is attachedto the machine.

ForksForks can wear out. The cumulative effects of age,abrasion, corrosion, overloading, and misuse canseverely weaken forks.

More frequent inspections will be required of olderwork tools and work tools that are used in particularlysevere operating conditions or in a rental fleet.

To perform a proper inspection, the forks must bethoroughly cleaned. It is impossible to inspect theforks properly if the work tool is dirty.

Inspect the forks before the forks are attached to themachine.

Perform the yearly inspection for the forks prior tothe start of each contract for all machines that areoperating in a rental fleet.

Inspect the forks for deformation. Check that theupright of the fork is at 90 degrees to the blade of thefork. Check the fork for cracks in the metal. Closelyinspect the area around the heel of the fork. This isthe area of the fork that is subject to the greateststresses. If a crack is visible, take the fork out ofservice immediately until the fork can be thoroughlyexamined.

Keep a record of each fork in order to establish aroutine of regular inspection. Include the followinginitial information in the record:

• Manufacturer of the fork

• Type of fork

• Original size of fork section

• Original length of the fork

Record the date of each inspection and the results ofeach inspection. Ensure that the following informationis included:

• Amount of wear on the blade

• Any damage, failure or deformation which mightimpair the use of the forks

• Any repairs or maintenance to the forks

An ongoing record of this information will help inidentifying appropriate inspection intervals for eachoperation and in identifying and solving problemareas and in anticipating time for replacement of theforks.

Daily Inspection

1. Visually inspect the forks for cracks. Lookparticularly for cracks in the heel of the forks andfor cracks around areas of weld. Look for tips offorks that are broken or bent. Look for twistedblades and shanks. Forks which are twistedshould be removed from service. Also, forks whichare cracked should be removed from service.

2. Make sure that the bolt for locking the fork is inplace and that the bolt is working. Lock the forksin position before you use the forks.

3. Remove all worn forks or damaged forks fromservice.

Yearly Inspection


Work Tool - Inspect/Replace


1. Inspect forks carefully for cracks. Pay specialattention to heel (A) and mounting brackets (B).Look for cracks around all areas of weld. Inspectthe tubes on forks that are mounted on shafts.

Forks with cracks should be removed from service.


2. Check the angle between the upper face of blade(D) and the front face of shank (E). Remove thefork from service if angle (C) exceeds 93 degrees.

3. Check the straightness of the upper face of blade(D) and the front face of shank (E) with a straightedge.

Remove the fork from service if the deviation fromstraightness exceeds 0.5 percent of the lengthof the blade. Remove the fork from service if thedeviation from height exceeds 0.5 percent of theheight of the shank.


4. Check the difference in the height of the tip of onefork against the height of the tip of the other forkwhen the forks are mounted on the carriage. Adifference in the height of the tip of the fork canresult in uneven support of the load. This couldcause problems when the forks are entering thepockets of the load.

The maximum recommended difference in theheight of the tip of the forks (F) is 6.5 mm(0.25 inch) for pallet forks. The maximumrecommended difference in the height of the tip ofthe forks (F) is 3 mm (0.125 inch) for fully taperedforks. The maximum allowable difference in theheight of the tips between two or more forks is 3percent of the length (L) of the blade .

Replace one or both forks when the differencein the height of the tip of the fork exceeds themaximum allowable difference.


5. Check the thickness (J) of the blade and thethickness (H) of the shank for wear. Pay specialattention to heel (A). Remove the fork from serviceif the thickness is reduced to 90 percent or lessof the original thickness.

176 SEBU7708-08Maintenance SectionWork Tool - Inspect/Replace

The length of the fork may also be reduced bywear, especially on tapered forks. Remove theforks from service when the length of the blade isno longer adequate for the intended loads.


6. Check markings (K) for readability. Renew themarkings if the markings are not legible.

Buckets

Mounting Bracket

Inspect the mounting brackets on the bucket andensure that the mounting plates are not bent orotherwise damaged. Inspect the angled plate andensure that the plate is not bent or otherwisedamaged. If any wear or damage is suspected,consult your Caterpillar dealer before you use thebucket.

Bucket Cutting Edges

Personal injury or death can result from bucketfalling.

Block the bucket before changing bucket cuttingedges.

1. Raise the bucket. Place a block under the bucket.

2. Lower the bucket to the block.

Do not block up the bucket too high. Block upthe bucket so that the bucket is high enough toremove the cutting edges and the end bits.

3. Remove the bolts. Remove the cutting edge andthe end bits.

4. Clean the contact surfaces.

5. Use the opposite side of the cutting edge, if thisside is not worn.

6. Install a new cutting edge, if both edges are worn.

7. Install the bolts. Tighten the bolts to the specifiedtorque. Refer to Specifications, SENR3130,“Torque Specifications”, “Ground Engaging ToolFasteners” for more information.

8. Raise the bucket. Remove the block.

9. Lower the bucket to the ground.

10.After a few hours of operation, check the boltsfor proper torque.

Bucket Wear Plates

Personal injury or death can result from fallingbucket.

When working under or around the bucket or link-age, with the bucket raised, proper support mustbe provided for the bucket and/or the linkage.

Replace the wear plates before damage to thebottom of the bucket occurs.

1. Raise the bucket and block up the bucket.

2. Loosen bolts and remove wear plates.

3. Install new wear plates. Tighten the bolts tothe specified torque. Refer to Specifications,SENR3130, “Torque Specifications”, “GroundEngaging Tool Fasteners” for more information.

SEBU7708-08 M

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