MAINTENANCE INTERVALS

Operation and Maintenance

Manual Excerpt

® ®
© 2010 Caterpillar
All Rights Reserved
 SEBU7824-11
October 2010

Operation and
Maintenance
Manual
385C Excavator and 385C MHPU
Mobile Hydraulic Power Unit
MMA1-Up (Machine)
KGB1-Up (Machine)
KBC1-Up (Machine)
SBE1-Up (Machine)
T2E1-Up (Machine)
T2F1-Up (Machine)
KKK1-Up (Machine)
EAM1-Up (Machine)
JCM1-Up (Machine)
M3W1-Up (Machine)

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232 SEBU7824-11
Maintenance Section
Maintenance Interval Schedule

i04082469 Windows - Clean ................................................. 290

Maintenance Interval Schedule Every 10 Service Hours or Daily for First 100
Hours
SMCS Code: 7000
Boom, Stick and Bucket Linkage - Lubricate ...... 237
Ensure that all safety information, warnings and
instructions are read and understood before any Every 10 Service Hours or Daily
operation or any maintenance procedures are
performed. Cooling System Coolant Level - Check .............. 249
Engine Oil Level - Check .................................... 256
The user is responsible for the performance of Fuel System Water Separator - Drain ................. 264
maintenance, including all adjustments, the use of Fuel Tank Water and Sediment - Drain ............... 265
proper lubricants, fluids, filters, and the replacement Hydraulic System Oil Level - Check ................... 277
of components due to normal wear and aging. Failure Indicators and Gauges - Test .............................. 279
to adhere to proper maintenance intervals and Seat Belt - Inspect .............................................. 281
procedures may result in diminished performance of Track Adjustment - Inspect ................................. 288
the product and/or accelerated wear of components. Travel Alarm - Test .............................................. 288
Undercarriage - Check ........................................ 289
Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST, Every 10 Service Hours or Daily for Machines
in order to determine the maintenance intervals. Used in Severe Applications
Products that operate in severe operating conditions
may require more frequent maintenance. Boom, Stick and Bucket Linkage - Lubricate ...... 237

Note: Before each consecutive interval is performed, Every 50 Service Hours or Weekly
all maintenance from the previous interval must be
performed. Boom, Stick and Bucket Linkage - Lubricate ...... 237

Note: If Cat HYDO Advanced 10 hydraulic oil is Every 100 Service Hours of Continuous
used, the hydraulic oil change interval is extended Hammer Use
to 3000 hours. S·O·S services may extend the oil
change to a longer interval. Consult your Caterpillar Hydraulic System Filter Element (Fine Filtration) -
dealer for details. Replace ............................................................. 267
Hydraulic System Oil Filter (Case Drain) -
When Required Replace ............................................................. 271
Hydraulic System Oil Filter (Pilot) - Replace ....... 272
Air Conditioner/Cab Heater Filter (Recirculation) -
Inspect/Replace ................................................ 234 Initial 250 Service Hours
Automatic Lubrication System Grease - Add ...... 234
Battery - Recycle ................................................ 236 Engine Valve Lash and Fuel Injector Timing -
Battery or Battery Cable - Inspect/Replace ........ 236 Check ................................................................ 259
Bucket Linkage - Inspect/Adjust ......................... 239 Final Drive Oil - Change ..................................... 260
Bucket Tips - Inspect/Replace ............................ 240 Hydraulic System Filter Element (Fine Filtration) -
Bucket Tips - Inspect/Replace ............................ 242 Replace ............................................................. 267
Cab Air Filter (Fresh Air) - Clean/Replace .......... 246 Hydraulic System Oil Filter (Case Drain) -
Circuit Breakers - Reset ...................................... 246 Replace ............................................................. 271
Counterweight Removal Chain - Inspect/Clean/ Hydraulic System Oil Filter (Pilot) - Replace ....... 272
Lubricate ........................................................... 252 Hydraulic System Oil Filter (Return) - Replace ... 273
Engine Air Filter Primary Element - Clean/ Swing Drive Oil - Change ................................... 282
Replace ............................................................. 252
Engine Air Filter Secondary Element - Replace .. 255 Every 250 Service Hours
Engine Air Precleaner - Clean ............................ 255 Cooling System Coolant Sample (Level 1) -
Ether Starting Aid Cylinder - Replace ................. 260
Obtain ............................................................... 250
Fuel System - Prime ........................................... 262
Engine Oil Sample - Obtain ................................ 257
Fuses - Replace .................................................. 265 Final Drive Oil Sample - Obtain .......................... 261
Hydraulic Tank Screen - Clean ........................... 277
Oil Filter - Inspect ................................................ 279
Radiator Core - Clean ......................................... 280
Every 250 Service Hours or Monthly
Track Adjustment - Adjust ................................... 287 Belt - Inspect/Adjust/Replace .............................. 237
Window Washer Reservoir - Fill .......................... 289 Condenser (Refrigerant) - Clean ........................ 247
Window Wiper - Inspect/Replace ........................ 290 Final Drive Oil Level - Check .............................. 261
SEBU7824-11 233
Maintenance Section
Maintenance Interval Schedule

Swing Bearing - Lubricate ................................... 281 Every 2000 Service Hours or 1 Year
Swing Drive Oil Level - Check ............................ 283
Engine Valve Lash and Fuel Injector Timing -
Every 250 Service Hours of Partial Hammer Check ................................................................ 259
Engine Valve Rotators - Inspect ......................... 259
Use (50% of Service Hours)
Final Drive Oil - Change ..................................... 260
Hydraulic System Filter Element (Fine Filtration) - Hydraulic System Oil - Change ........................... 268
Replace ............................................................. 267 Receiver Dryer (Refrigerant) - Replace .............. 280
Hydraulic System Oil Filter (Case Drain) - Swing Gear - Lubricate ....................................... 285
Replace ............................................................. 271 Swing Gear - Lubricate ....................................... 286
Hydraulic System Oil Filter (Pilot) - Replace ....... 272
Every Year
Every 250 Service Hours of Continuous
Cooling System Coolant Sample (Level 2) -
Hammer Use Obtain ............................................................... 251
Hydraulic System Oil Filter (Return) - Replace ... 273
Every 3000 Service Hours or 18 Months
Initial 500 Hours (for New Systems, Refilled Hydraulic System Oil - Change ........................... 268
Systems, and Converted Systems)
Cooling System Coolant Sample (Level 2) - Every 3 Years After Date of Installation or
Obtain ............................................................... 251 Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 281
Every 500 Service Hours
Hydraulic System Oil Sample - Obtain ............... 277 Every 6000 Service Hours or 3 Years
Swing Drive Oil Sample - Obtain ........................ 284
Cooling System Coolant Extender (ELC) - Add .. 248
Every 500 Service Hours or 3 Months
Every 12 000 Service Hours or 6 Years
Engine Crankcase Breather - Clean ................... 256
Cooling System Coolant (ELC) - Change ........... 247
Engine Oil and Filter - Change ........................... 257
Fuel System Primary Filter (Water Separator)
Element - Replace ............................................ 262
Fuel System Secondary Filter - Replace ............ 263
Fuel Tank Cap and Strainer - Clean ................... 264
Hydraulic System Filter Element (Fine Filtration) -
Replace ............................................................. 267
Hydraulic System Oil Filter (Case Drain) -
Replace ............................................................. 271
Hydraulic System Oil Filter (Pilot) - Replace ....... 272

Every 500 Service Hours of Partial Hammer

Use (50% of Service Hours)
Hydraulic System Oil Filter (Return) - Replace ... 273

Every 600 Service Hours of Continuous

Hammer Use
Hydraulic System Oil - Change ........................... 268

Every 1000 Service Hours or 6 Months

Battery - Clean .................................................... 236
Battery Hold-Down - Tighten ............................... 236
Hydraulic System Oil Filter (Return) - Replace ... 273
Swing Drive Oil - Change ................................... 282

Every 1000 Service Hours of Partial Hammer

Use (50% of Service Hours)
Hydraulic System Oil - Change ........................... 268
234 SEBU7824-11
Maintenance Section
Air Conditioner/Cab Heater Filter (Recirculation) - Inspect/Replace

i04000735 i02236533

Air Conditioner/Cab Heater Automatic Lubrication System

Filter (Recirculation) - Grease - Add
Inspect/Replace (If Equipped)
SMCS Code: 1054-040-A/C; 1054-510-A/C SMCS Code: 7540

NOTICE The grease reservoir is inside the left storage box.

An air recirculation filter element plugged with dust will
result in decreased performance and service life to the
air conditioner or cab heater.
The lines and the pipes in the automatic lubrica-
To prevent decreased performance, clean the filter el- tion system are under extremely high pressure.
ement, as required.
Do not loosen any joints or plugs while the pump
is operating.

Serious injury can result from high pressure

grease spraying out suddenly.

g01100988
Illustration 323

The air conditioner filter is located on the lower left

side of the cab behind the seat.

1. Slide the operator seat forward. Illustration 324

g00587364

(1) “MAX” level

2. Slide the filter element upward. (2) “MIN” level

3. Tap the air filter in order to remove the dirt. Do not 1. Inspect the level of the reservoir when a message
use compressed air to clean the filter. appears on the display which indicates that the
level of grease in the grease reservoir is low.
4. After you clean the filter element, inspect the filter
element. If the filter element is damaged or badly
contaminated, use a new filter element. Make sure NOTICE
that the filter element is dry. Make sure that the grease level does not fall below the
“MIN” level in the reservoir. The operation of the au-
5. Install the filter element. tomatic lubrication system with the grease level below
“MIN” will damage the front pins and the swing bearing
because not enough grease will be supplied to these
NOTICE areas.
Failure to reinstall the filter element for the air condi-
tioning system will contaminate and damage the sys-
tem components. 2. If the grease level is lower than “MIN” (2), grease
should be added to the reservoir.
SEBU7824-11 235
Maintenance Section
Automatic Lubrication System Grease - Add

4. Remove cap (5) from the fill port of the electric

NOTICE pump (6).
NLGI Grade 0 grease or NLGI Grade 1 grease that has
a low viscosity should be used only in cold weather
conditions. The consumption of grease will increase if
used in warmer weather.

NOTICE
Any foreign materials that enter the grease reservoir
could restrict the lubrication lines or damage the
valves. Prior to adding the grease to the reservoir,
be sure to wipe any potential contaminants from the
grease fitting and the grease gun nozzle.

NOTICE
When you add grease to the grease reservoir, nev-
er add the grease beyond the “MAX” level. If you add
grease above this level, the cover of the grease reser-
voir could come off during operation. The capacity of
the grease reservoir is 8 L (2.1 US gal).

g00607272
Illustration 327
(3) Grease gun
(6) Electric pump

5. Unscrew the cap from the tip of grease gun (3).

Attach the end of the grease gun to the threaded
fill port that is on top of electric pump (6).

6. Tighten the grease gun until the head of the thread

is in contact with the fill port.

g00607270
Illustration 325
(3) Grease gun
(4) Grease cartridge

3. Install grease cartridge (4) in grease gun (3). The

grease gun is located in the storage box.

g00607273
Illustration 328
(1) “MAX” level
(2) “MIN” level
g00607271 (3) Grease gun
Illustration 326
(5) Filler cap
(5) Filler cap (7) Handle
(6) Electric pump
236 SEBU7824-11
Maintenance Section
Battery - Clean

7. Gradually push handle (7) of grease gun (3) until i04064489

the reservoir is filled to the “MAX” level.
Battery or Battery Cable -
8. After the supply of grease is finished, remove
grease gun (3). Clean the fill port and install cap
Inspect/Replace
(5). SMCS Code: 1401-040; 1401-510; 1401-561; 1401;
1402-040; 1402-510
Use a multipurpose type grease that contains three
to five percent molybdenum. Use NLGI Grade 2
grease that meets the requirements for cold weather
conditions and hot weather conditions.
Personal injury can result from battery fumes or
explosion.
i00934864
Batteries give off flammable fumes that can ex-
Battery - Clean plode. Electrolyte is an acid and can cause per-
sonal injury if it contacts the skin or eyes.
SMCS Code: 1401-070
Prevent sparks near the batteries. Sparks could
Clean the battery surface with a clean cloth. Keep the cause vapors to explode. Do not allow jumper ca-
terminals clean and keep the terminals coated with ble ends to contact each other or the engine. Im-
petroleum jelly. Install the post cover after you coat proper jumper cable connections can cause an ex-
the terminal post with petroleum jelly. plosion.

i00993589 Always wear protective glasses when working

with batteries.
Battery - Recycle
SMCS Code: 1401-561 1. Turn all of the switches to the OFF position. Turn
the engine start switch key to the OFF position.
Always recycle a battery. Never discard a battery.
2. Turn the battery disconnect switch to the OFF
Always return used batteries to one of the following position. Remove the key.
locations:
3. Disconnect the negative battery cable at the
battery.
• A battery supplier
4. Disconnect the positive battery cable at the
• An authorized battery collection facility battery.
• Recycling facility 5. Disconnect the battery cables at the battery
disconnect switch. The battery disconnect switch
i00934872 is connected to the machine frame.
Battery Hold-Down - Tighten 6. Make necessary repairs or replace the battery.
SMCS Code: 7257 7. Connect the battery cable at the battery disconnect
switch.
Tighten the hold-downs for the battery in order to
prevent the batteries from moving during machine 8. Connect the positive battery cable of the battery.
operation.
9. Connect the negative battery cable of the battery.

10. Install the key and turn the battery disconnect

switch to the ON position.
SEBU7824-11 237
Maintenance Section
Belt - Inspect/Adjust/Replace

i02235410 i03865613

Belt - Inspect/Adjust/Replace Boom, Stick and Bucket

SMCS Code: 1357-025; 1357-040; 1357-510; Linkage - Lubricate
1397-025; 1397-040; 1397-510
SMCS Code: 6501-086; 6502-086; 6513-086
Note: This engine is equipped with a belt tightener
Note: Caterpillar recommends the use of 5%
that automatically adjusts the belt to the correct
molybdenum grease for lubricating the boom,
tension.
stick, and bucket linkage. Refer to Special
Publication, SEBU6250, “Caterpillar Machine
1. Unlatch the engine hood and raise the engine
Fluids Recommendations” for more information on
hood.
molybdenum grease.
2. Inspect the belt for wear and for cracking.

3. If the belt requires replacement, perform Step 3.a

through Step 3.c.

g02109428
Illustration 330

Wipe all fittings before you apply lubricant.

g01127241
Illustration 329 Illustration 331
g01122104

a. Turn the belt tensioner in order to release the 1. Apply lubricant through the fitting at the base of
tension from the belt. each boom cylinder.
b. Remove the belt.

c. Install a new belt.

4. Close the engine hood.

238 SEBU7824-11
Maintenance Section
Boom, Stick and Bucket Linkage - Lubricate

g00685798 g01122102
Illustration 332 Illustration 334

2. The fittings are at the base of the boom. The 6. Apply lubricant through fitting (13). Fitting (13) is at
fittings can be serviced from the platform on the the connection point of the boom and of the stick.
storage box. To lubricate the lower boom bearings,
apply lubricant through fittings (1) and (2). To
lubricate the boom cylinder rod, apply lubricant
through fittings (3) and (4). To lubricate the stick
cylinder head, apply lubricant through fitting (5).

Note: To ensure proper lubrication of the lower boom

bearings and of the boom cylinder rod end bearings,
lubricant should be applied through fittings (1), (2),
(3), and (4). Apply lubricant first when the boom is
raised and any work tool is suspended. Then apply
lubricant when the boom is lowered and the work
tool is rested on the ground with a slight downward
pressure.
g01122103
Illustration 335

7. Apply lubricant through fitting (14) on the stick

cylinder rod. Apply lubricant through fitting (15).
Fitting (15) is at the connection point of the boom
and of the stick. Apply lubricant through fitting (16)
on the bucket cylinder head end.

g01396856
Illustration 333

3. Apply lubricant through fittings (6) and (7). These

fittings are on the bucket.

4. Apply lubricant through fittings (8) and (9). These

fittings are on the stick.

5. Apply lubricant through fittings (10), (11), and (12).

These fittings are on the link.
SEBU7824-11 239
Maintenance Section
Bucket Linkage - Inspect/Adjust

Grease Block on the Stick

g01141595
Illustration 337
g01396894
Illustration 336 (1) No gap
(13) Left side connection point of boom and stick (2) Stick boss
(14) Stick cylinder rod (3) Bucket clearance
(15) Right side connection point of boom and stick (4) Shims
(16) Bucket cylinder head end (5) Plate
(6) Pin
(7) Plate
Some machines may be equipped with a grease (8) Bolts
block that is located on the stick. Apply lubricant (9) Washers
through the fittings. (10) Bolts
(11) Washers
(12) Location
(13) Flange
i03933249
(14) Bucket boss
Bucket Linkage - The clearance of the bucket control linkage on
Inspect/Adjust this machine can be adjusted by shimming. If the
gap between the bucket and the stick becomes
SMCS Code: 6513-025; 6513-040 excessive, adjust bucket clearance (3) to 0.5 to 1 mm
(0.02 to 0.04 inch).

Two shims of different thickness are used at location

Unexpected machine movement can cause injury (12). The thicknesses of the shims are 0.5 mm
or death. (0.02 inch) and 1.0 mm (0.04 inch).

To avoid possible machine movement, move the

hydraulic lockout control to the locked position
and attach a Special Instruction, SEHS7332, “Do
Not Operate” or similar warning tag to the hy-
draulic lockout control.

NOTICE
Improperly adjusted bucket clearance could cause
galling on the contact surfaces of the bucket and
stick, resulting in excessive noise and/or damaged
O-ring seals.

g02109636
Illustration 338
Area for linkage adjustment

1. Position the machine on a level surface and lower

the bucket to the ground.
240 SEBU7824-11
Maintenance Section
Bucket Tips - Inspect/Replace

2. Slowly operate the swing control lever until stick

boss (2) and the bucket boss (14) are in full face
contact at no gap (1). This will help to determine
the total clearance of the connection point of the
stick and of the bucket.

3. Move the hydraulic lockout control to the LOCKED

position. Stop the engine.

4. Measure bucket clearance (3), which is the

existing total clearance.

5. Determine the number of shims that need to be

removed from shims (4) by using the following
calculation: g00101352
Illustration 339
Subtract 0.5 mm (0.02 inch) or 1.0 mm (0.04 inch) (1) Usable
from bucket clearance (3). (2) Replace
(3) Overworn

6. Remove the appropriate number of shims at

Check the bucket tips for wear. If the bucket tip has a
location (12) in order to meet the above thickness.
hole, replace the bucket tip.
Make sure that you use a minimum of three
0.5 mm (0.02 inch) shims. To remove the shims,
remove bolts (8), washers (9), plate (7), bolts (10), Removal
washers (11), and plate (5).

7. After the correct number of shims has been

removed and pin (6) is aligned with the pin hole,
install plate (5), washers (11), bolts (10), plate (7),
washers (9), and bolts (8). Tighten the bolts to a
torque of 240 ± 40 N·m (175 ± 30 lb ft).

8. After installation, make sure that bucket clearance

(3) is still correct.

i03574841

Bucket Tips - Inspect/Replace

g01389463
Illustration 340
SMCS Code: 6805-040; 6805-510
Note: Retainers are often damaged during the
removal process. Caterpillar recommends the
installation of a new retainer when bucket tips are
Personal injury or death can result from the bucket rotated or replaced.
falling.

Block the bucket before changing bucket tips.

Note: In order to maximize the life of the bucket tip

and the penetration of the bucket tip, the bucket tip
can be rotated.

g01175361
Illustration 341
SEBU7824-11 241
Maintenance Section
Bucket Tips - Inspect/Replace

1. Use a pry bar in order to disengage retainer (5). 1. Remove the mounting bolts and the side cutters.

2. Use the pry bar in order to remove retainer (5) 2. Clean the mounting surface of the side plate on
from bucket tip (4). the bucket and of the side cutter. Remove any
burrs or protrusions on the mating surfaces.
3. Remove bucket tip (4) from adapter (6) with a
slight counterclockwise rotation.

4. Clean adapter (6).

Installation
1. Clean the adapter and the area around the latch,
if necessary.

2. Install the new bucket tip onto the adapter with a

slight clockwise rotation.

g01389456
Illustration 344
(7) Side cutter

Note: Some side cutters may be rotated for additional

wear.

3. Install the side cutter.

Note: Certain bolts may require thread compound.

4. Hand tighten the bolts.

g01124736
Illustration 342

3. Install the retainer. Make sure that the retainer's

latch catches under the tip pocket.

4. Make sure that the latch is properly seated by

trying to remove the bucket tip.

Side Cutters (If Equipped)

g01389457
Illustration 345
Section A-A From Illustration 344
(8) Side cutter
(9) Shear ledge on a side cutter
(10) Side plate on a bucket
(11) 0.0 mm (0.0 inch)

5. Make sure that there is not a gap between the

side plate on the bucket and the shear ledge on
the side cutter.
g01389740
Illustration 343 6. Torque the mounting bolts to the correct
Bucket with side cutters specification.
Side cutters
242 SEBU7824-11
Maintenance Section
Bucket Tips - Inspect/Replace

Side Protectors (If Equipped) 2. Clean side protector (12), pin (13), retainer (14)
and side plate (15) before installation.
Inspect the wear of the side protector. When too
much wear is present, replace the protector. Note: Lateral clearance between the side plate
and the side protector should not exceed 1 mm
(0.04 inch). Shims (16) may be required in order to
decrease the lateral clearance which will decrease
movement. Install the shims(16) between the side
plate and the side protector on the opposite side of
the retainer.

3. Put retainer (14) in side plate (15).

4. Align two pin holes of the new protector and the

side plate. Hit the pin from the retainer side of the
bucket.

Note: If the pin and/or the retainer are worn, replace

the pin and/or the retainer.
g01389458
Illustration 346

i03574842

Bucket Tips - Inspect/Replace

SMCS Code: 6805-040; 6805-510

Block the bucket before changing the bucket

teeth.

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

tective face shield when striking the pin.
g01903698
Illustration 347 The pin, when struck, can fly out and cause injury
to nearby personnel.

Bucket Tips

g01389459
Illustration 348
(12) Side protector
(13) Pin
(14) Retainer
(15) Side plate
g01577934
(16) Shim Illustration 349
(1) Usable tip
1. Hit pin (13) from the side of the bucket without (2) Replaceable bucket tip
the retainer in order to remove side protector (12) (3) Overworn tip
from side plate (15).
Check the bucket tips for wear. If the bucket tip has a
hole, replace the bucket tip.
SEBU7824-11 243
Maintenance Section
Bucket Tips - Inspect/Replace

1. Remove the pin from the bucket tip. The pin can
be removed by one of the following methods.

• Use a hammer and a punch from the retainer

side of the bucket to drive out the pin.

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

1.c for the procedure.

g01577913
Illustration 351
(6) Retainer assembly
(7) Adapter

2. Clean the adapter and the pin.

3. Fit retainer assembly (6) into the counterbore that

is in the side of adapter (7). Make sure that the
face of the retainer assembly with the marking
“OUTSIDE” is visible.

g01577993
Illustration 350
(4) Back of Pin-Master
(5) Extractor

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

b. Align extractor (5) with the pin.

c. Strike the Pin-Master at the back of the tool (4)

and remove the pin.
g00101359
Illustration 352
Note: Discard the old pin and the retainer assembly.
When you change tips, use a new pin and a new 4. Install the new bucket tip onto the adapter.
retainer assembly. Refer to the appropriate parts
manual for your machine. Note: The bucket tips can be rotated by 180 degrees
in order to allow the tip to wear evenly. You may also
move the tips from the outside teeth to the inside
teeth. Check the tips often. If wear is present on the
tips, rotate the tips. The outside teeth generate the
most wear.

5. Drive the pin through the bucket tip. The pin can
be installed by using one of the following methods:

• From the same side of the retainer, drive the pin

through the bucket tip, the retainer assembly,
and the adapter.

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

5.e for the procedure.
244 SEBU7824-11
Maintenance Section
Bucket Tips - Inspect/Replace

g01578233 g01209159
Illustration 353 Illustration 355
(8) Pin Final assembly of pin into bucket tip

a. Insert pin (8) through the bucket tip. e. Strike the end of the tool until the pin is fully
inserted.

Side Cutters

g01578342
Illustration 354

b. Place the Pin-Master over the bucket tips so

that the pin will fit into the counterbore of the Illustration 356
g01579693
pin holder (9).
Bucket With Side Cutters

c. Strike the Pin-Master with a hammer at the

1. Remove the mounting bolts and the side cutters
back of the tool (4) in order to insert the pin.
(11).
d. Slide pin holder (9) away from the pin and
2. Clean the mounting surface of the side plate on
rotate the tool slightly in order to align pin setter
the bucket and of the side cutter. Remove any
(10) with the pin.
burrs or protrusions on the mating surfaces.
SEBU7824-11 245
Maintenance Section
Bucket Tips - Inspect/Replace

g01592996
Illustration 358

g01579713
Illustration 357
(12) Shear ledge on a side cutter
(13) Side plate on a bucket
(B) 0.0 mm (0.0 inch)

Note: Some side cutters may be rotated for additional

wear.

3. Install the side cutter.

g01903678
Illustration 359
Note: Certain bolts may require thread compound.
(14) Side plate
(15) Retainer
4. Hand tighten the bolts. (16) Side protector
(17) Pin
5. Make sure that there is not a gap between the (18) Shim
side plate on the bucket and the shear ledge on
the side cutter. 1. Hit pin (17) from the side of the bucket without
the retainer in order to remove side protector (16)
6. Torque the mounting bolts to the correct from side plate (14).
specification.
2. Clean side protector (16), pin (17), retainer (15)
and side plate (14) before installation.
Side Protectors (If Equipped)
Note: Lateral clearance between the side plate
Inspect the wear of the side protector. When too and the side protector should not exceed 1 mm
much wear is present, replace the protector. (0.04 inch). Shims (18) may be required in order to
decrease the lateral clearance which will decrease
movement. Install the shims (18) between the side
plate and the side protector on the opposite side of
the retainer.

3. Put retainer (15) in side plate (14).

246 SEBU7824-11
Maintenance Section
Cab Air Filter (Fresh Air) - Clean/Replace

4. Align two pin holes of the new protector and the 4. After you clean the air filter, inspect the air filter.
side plate. Hit the pin from the retainer side of the If the air filter is damaged or badly contaminated,
bucket. use a new air filter.

Note: If the pin and/or the retainer are worn, replace 5. Install the air filter and the filter cover.
the pin and/or the retainer.
Note: Make sure that the arrow on top of the air filter
is facing forward.
i01547055

Cab Air Filter (Fresh Air) - i02173231

Clean/Replace Circuit Breakers - Reset

SMCS Code: 7342-070; 7342-510
SMCS Code: 1420-529

g00730030
Illustration 360 Illustration 362
g01101328
(1) Bolt The circuit breaker is located behind the front left access door.
(2) Filter cover

Main Circuit – This circuit breaker is

The cab air filter is behind the cab.
designed to protect the wires between the
batteries and the fuses. If the wires are
1. Loosen bolt (1) and open filter cover (2).
shorted to the machine's body, this circuit breaker
would minimize the damage to the wires.

The main circuit breaker has a capacity of 80 Amp.

Circuit Breaker Reset – Push in the button in order

to reset the circuit breaker. If the electrical system is
working properly, the button will remain depressed.
If the button does not remain depressed, check the
appropriate electrical circuit. Repair the electrical
circuit, if necessary.

g00730032
Illustration 361
(2) Filter cover
(3) Air filter

2. Remove air filter (3) from filter cover (2).

3. Clean the air filter with a maximum of 200 kPa

(30 psi) pressure air.
SEBU7824-11 247
Maintenance Section
Condenser (Refrigerant) - Clean

i02269887 i03133221

Condenser (Refrigerant) - Cooling System Coolant (ELC)

Clean - Change
SMCS Code: 1805-070 SMCS Code: 1350-044

NOTICE NOTICE
If excessively dirty, clean condenser with a brush. To Mixing Extended Life Coolant (ELC) with other prod-
prevent damage or bending of the fins, do not use a ucts reduces the effectiveness of the coolant and
stiff brush. shortens coolant life. Use only Caterpillar prod-
ucts or commercial products that have passed the
Repair the fins if found defective. Caterpillar EC-1 specifications for premixed or con-
centrate coolants. Use only Caterpillar Extender with
Caterpillar ELC. Failure to follow these recommenda-
1. Open the middle access panel on the left side of tions could result in the damage to cooling systems
the machine. components.

If ELC cooling system contamination occurs, refer to

Special Publication, SEBU6250, “Cat Extended Life
Coolant (ELC)”.

This machine was factory filled with Extended Life

Coolant.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
g00537515
ing any compartment or disassembling any compo-
Illustration 363 nent containing fluids.
2. Inspect the condenser for debris. Clean the Refer to Special Publication, NENG2500, “Caterpillar
condenser, if necessary. Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
3. Use clean water to wash off all dust and dirt from products.
the condenser.
Dispose of all fluids according to local regulations and
4. Close the access door. mandates.

g01107218
Illustration 364
248 SEBU7824-11
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

1. Open the access cover for the cooling system

pressure cap. The access cover for the cooling
system pressure cap is located on top of the
machine above the left rear access panel.

2. Slowly loosen the cooling system pressure cap

in order to release pressure. Remove the cooling
system pressure cap.

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information that
pertains to containing fluid spillage.

3. Open the drain valve that is on the bottom of the

radiator. The drain valve can be reached through g01105831
the small access hole that is located next to the Illustration 365
drain hose on the underside of the machine. Allow Coolant reservoir
the coolant to drain into a suitable container. (1) “FULL”
(2) “LOW”
Note: Dispose of drained fluids according to local
regulations. 13. Check the coolant reservoir. Maintain the coolant
level between the “FULL” mark (1) and the “LOW”
4. Flush the cooling system with clean water until the mark (2).
draining water is clean.
14. If additional coolant is necessary, remove the
5. Close the drain valve. reservoir cap on top of the coolant reservoir and
add the appropriate coolant solution.
6. Add the Extended Life Coolant. See Operation
and Maintenance Manual, “Capacities (Refill)”. 15. Install the reservoir cap.

7. Start the engine. Operate the engine without 16. Close the small storage compartment.
the cooling system pressure cap until the water
temperature regulator opens and the coolant level 17. Close the left rear access panel and install the
stabilizes. bolts for the left rear access panel.

8. Maintain the coolant level within 13 mm (0.5 inch)

i02192049
of the bottom of the filler pipe.
Cooling System Coolant
9. Check the gasket of the cooling system pressure
cap. If the gasket is damaged, replace the Extender (ELC) - Add
pressure cap.
SMCS Code: 1352; 1353; 1395
10. Install the cooling system pressure cap and close
the access cover for the cooling system pressure When a Caterpillar Extended Life Coolant (ELC) is
cap. used, an Extender must be added to the cooling
system. See Special Publication, SEBU6250,
11. Stop the engine. “Cooling Recommendations” for all cooling system
requirements.
12. Open the small storage compartment that
is located on the floor in front of the engine Use a coolant conditioner test kit in order to check
compartment. the concentration of the coolant.
SEBU7824-11 249
Maintenance Section
Cooling System Coolant Level - Check

• Operation and Maintenance Manual, “Capacities

NOTICE (Refill)”
Mixing Extended Life Coolant (ELC) with other prod-
ucts reduces the effectiveness of the coolant and 5. Inspect the gasket of the cooling system pressure
shortens coolant life. Use only Caterpillar prod- cap. If the gasket is damaged, replace the
ucts or commercial products that have passed the pressure cap.
Caterpillar EC-1 specifications for premixed or con-
centrate coolants. Use only Caterpillar Extender with 6. Install the cooling system pressure cap.
Caterpillar ELC. Failure to follow these recommenda-
tions could result in the damage to cooling systems 7. Close the access door for the cooling system
components. pressure cap.

If ELC cooling system contamination occurs, refer to

i02208390
Special Publication, SEBU6250, “Cat Extended Life
Coolant (ELC)”. Cooling System Coolant Level
This machine was factory filled with Extended Life - Check
Coolant.
SMCS Code: 1350-040; 1350-535-FLV;
1395-535-FLV

1. Open the small storage compartment that

is located on the floor in front of the engine
compartment.

g01107218
Illustration 366

1. Open the access cover for the cooling system

pressure cap.

2. Slowly loosen the cooling system pressure cap g01105831

Illustration 367
in order to release system pressure. Remove the
pressure cap. Coolant reservoir
(1) “FULL”
Note: Refer to Operation and Maintenance Manual, (2) “LOW”
“General Hazard Information” for information on
containing fluid spillage. 2. Check the coolant level of the coolant reservoir.
Maintain the coolant level between the “FULL”
3. It may be necessary to drain some coolant from mark and the “LOW” mark. If the coolant reservoir
the radiator so that Caterpillar Extender can be is empty, follow Steps 2.a through 2.i.
added to the cooling system.

Note: Always discard drained fluids according to

local regulations.

4. Add Extender to the cooling system. Refer to

the following topics for the proper amount of
Caterpillar Extender:

• Special Publication, SEBU6250, “Cat Extended

Life Coolant (ELC)”
250 SEBU7824-11
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain

f. Inspect the condition of the gasket on the

pressure cap. If the gasket is damaged, replace
the pressure cap.

g. Install the cooling system pressure cap.

h. Stop the engine.

i. Close the access cover for the cooling system

pressure cap.

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information on
containing fluid spillage.
g01107218
Illustration 368 3. If additional coolant is necessary, remove the
reservoir cap and add the appropriate coolant
a. Open the access cover for the cooling system solution.
pressure cap.
4. Install the reservoir cap.
b. Slowly loosen the cooling system pressure cap
in order to relieve system pressure. Remove 5. Close the left access door.
the pressure cap.

Note: Refer to Operation and Maintenance Manual, i03134107

“General Hazard Information” for information on
containing fluid spillage. Cooling System Coolant
Sample (Level 1) - Obtain
c. Add the appropriate coolant solution to the
cooling system. Refer to the following topics: SMCS Code: 1395-008; 1395-554; 7542

• Operation and Maintenance Manual, Note: It is not necessary to obtain a Coolant

SEBU6250, “Cooling System Specifications” Sample (Level 1) if the cooling system is filled
with Cat ELC (Extended Life Coolant). Cooling
• Operation and Maintenance Manual, systems that are filled with Cat ELC should have
“Capacities (Refill)” a Coolant Sample (Level 2) that is obtained at
the recommended interval that is stated in the
d. Start the engine. Operate the engine without Maintenance Interval Schedule.
the cooling system pressure cap until the water
temperature regulator opens and the coolant Note: Obtain a Coolant Sample (Level 1) if the
level stabilizes. cooling system is filled with any other coolant
instead of Cat ELC. This includes the following
e. Maintain the coolant level within 13 mm types of coolants.
(0.5 inch) of the bottom of the filler pipe.
• Commercial long life coolants that meet the
Caterpillar Engine Coolant Specification -1
(Caterpillar EC-1)

• Cat Diesel Engine Antifreeze/Coolant (DEAC)

• Commercial heavy-duty coolant/antifreeze

NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
Illustration 369
g00102170 rect interpretation that could lead to concerns by both
dealers and customers.
SEBU7824-11 251
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain

Note: Level 1 results may indicate a need for For additional information about coolant analysis, see
Level 2 Analysis. Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” or consult your Caterpillar
dealer.

i02049802

Cooling System Coolant

Sample (Level 2) - Obtain
SMCS Code: 1395-008; 1395-554; 7542

Reference: Refer to Operation and Maintenance

Manual, “Cooling System Coolant Sample (Level 1)
- Obtain” for the guidelines for proper sampling of
the coolant.
g01114744
Illustration 370
Coolant sample port Obtain the sample of the coolant as close as possible
to the recommended sampling interval. Supplies
Refer to the Operation and Maintenance Manual, for collecting samples can be obtained from your
“Access Doors and Covers” for the location of the Caterpillar dealer.
service points.
Submit the sample for Level 2 analysis.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order Reference: For additional information about coolant
to receive the full effect of S·O·S analysis, you analysis, refer to Special Publication, SEBU6250,
must establish a consistent trend of data. In order “Caterpillar Machine Fluids Recommendations” or
to establish a pertinent history of data, perform consult your Caterpillar dealer.
consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.

Use the following guidelines for proper sampling of

the coolant:

• Complete the information on the label for the

sampling bottle before you begin to take the
samples.

• Keep the unused sampling bottles stored in plastic

bags.

• Obtain coolant samples directly from the coolant

sample port. You should not obtain the samples
from any other location.

• Keep the lids on empty sampling bottles until you

are ready to collect the sample.

• Place the sample in the mailing tube immediately

after obtaining the sample in order to avoid
contamination.

• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.
Submit the sample for Level 1 analysis.
252 SEBU7824-11
Maintenance Section
Counterweight Removal Chain - Inspect/Clean/Lubricate

i02961473 3. Lubricate the surfaces between each link plate

edge (1) and roller (2) with SAE 30 engine oil.
Counterweight Removal Chain
- Inspect/Clean/Lubricate 4. If necessary, remove the entire chain assembly.

(If Equipped) 5. Clean the chain assembly with a clean,

nonflammable solvent and a wire brush.
SMCS Code: 7056-040-CX; 7056-070-CX;
7056-086-CX 6. Allow the chain assembly to dry. Lubricate the
surfaces between each link plate edge (1) and
roller (2).

Proper operation of the Counterweight Removal 7. If the chain assembly was removed, install the
System depends on a properly lubricated counter- chain assembly.
weight chain. If the chain is not lubricated prop-
erly, the chain may rust and seize during the re- i02270041
moval operation. A seized chain can fracture and
result in complete failure of the chain. The coun- Engine Air Filter Primary
terweight can then suddenly fall which can result
in personal injury or death. Element - Clean/Replace
Visually inspect the top of the counterweight SMCS Code: 1054-070; 1054-510
chain for proper lubrication and rusting on a
monthly basis. Lubricate the top of the chain, as 1. Open the top access door on the right side of the
required with 30 wt engine oil. Always lubricate machine.
the chain during removal of the counterweight, af-
ter the counterweight is lowered to the blocks on
the ground. Use an approved ladder or platform
when lubricating the upper portion of the chain.

If seizure of the chain occurs during counter-

weight removal, stop the operation of the counter-
weight removal system and contact your nearest
dealer for chain replacement.

The counterweight removal chain must be clean and

free from rust. A chain with dirt or rust cannot be
wound correctly.
g00561344
1. Inspect the chain. Illustration 372

2. Remove any foreign material and rust from the 2. Loosen the two cover clamps and remove the air
chain. cleaner cover.

g00115489 g00101415
Illustration 371 Illustration 373
(1) Link plate edge. (2) Roller.
SEBU7824-11 253
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace

3. Remove the primary filter element from the air Cleaning Primary Air Filter
cleaner housing.
Elements
4. Clean the air cleaner cover and the inside of the
air cleaner housing. NOTICE
Caterpillar recommends certified air filter cleaning ser-
5. Inspect the O-ring seal on the air cleaner cover. vices available at participating Caterpillar dealers. The
Replace the O-ring seal if the O-ring seal is worn Caterpillar cleaning process uses proven procedures
or damaged. to assure consistent quality and sufficient filter life.

6. Inspect the primary filter. If the primary filter Observe the following guidelines if you attempt to
element is not damaged, you can clean the clean the filter element:
primary element.
Do not tap or strike the filter element in order to re-
Refer to “Cleaning Primary Air Filter Elements”. move dust.

Do not wash the filter element.

Use low pressure compressed air in order to remove

the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.

Do not use air filters with damaged pleats, gaskets, or

seals. Dirt entering the engine will cause damage to
engine components.

g00102884 The primary air filter element can be used up to six

Illustration 374
times if the element is properly cleaned and if the
element is properly inspected. When the primary
7. Direct air along the pleats inside the primary filter air filter element is cleaned, check for rips or tears
element and outside the primary filter element. in the filter material. The primary air filter element
should be replaced at least one time per year. This
8. Inspect the primary filter element after cleaning. replacement should be performed regardless of the
Do not use a primary filter element with damaged number of cleanings.
pleats, damaged gaskets or damaged seals.

9. Encase the clean primary filter element and store NOTICE

the clean primary filter element in a clean, dry Do not clean the air filter elements by bumping or tap-
place. ping. This could damage the seals. Do not use ele-
ments with damaged pleats, gaskets, or seals. Dam-
10. Install the clean primary filter. aged elements will allow dirt to pass through. Engine
damage could result.
11. Install the air cleaner cover and close the latches
securely. Visually inspect the primary air filter elements before
cleaning. Inspect the air filter elements for damage
12. Change the filter if any of the following conditions to the seal, the gaskets, and the outer cover. Discard
occurs: any damaged air filter elements.
• Restricted Air Filter indicator on the monitor There are two common methods that are used to
panel still comes on. clean primary air filter elements:
• Exhaust smoke is still black after the installation • Pressurized air
of a primary filter.

Note: The primary filter can be cleaned up to six

• Vacuum cleaning
times. Replace the primary filter if the primary filter
has been used for one year.
254 SEBU7824-11
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace

Pressurized Air Inspecting the Primary Air Filter

Pressurized air can be used to clean primary air filter
Elements
elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi).

g00281693
Illustration 376

Inspect the clean, dry primary air filter element. Use

a 60 watt blue light in a dark room or in a similar
g00281692
facility. Place the blue light in the primary air filter
Illustration 375 element. Rotate the primary air filter element. Inspect
the primary air filter element for tears and/or holes.
Note: When the primary air filter elements are Inspect the primary air filter element for light that may
cleaned, always begin with the clean side (inside) show through the filter material. If it is necessary in
in order to force dirt particles toward the dirty side order to confirm the result, compare the primary air
(outside). filter element to a new primary air filter element that
has the same part number.
Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent Do not use a primary air filter element that has any
damage to the paper pleats. Do not aim the stream of tears and/or holes in the filter material. Do not use
air directly at the primary air filter element. Dirt could a primary air filter element with damaged pleats,
be forced further into the pleats. gaskets or seals. Discard damaged primary air filter
elements.
Vacuum Cleaning
Storing Primary Air Filter Elements
Vacuum cleaning is another method for cleaning
primary air filter elements which require daily cleaning If a primary air filter element that passes inspection
because of a dry, dusty environment. Cleaning with will not be used, the primary air filter element can
pressurized air is recommended prior to vacuum be stored for future use.
cleaning. Vacuum cleaning will not remove deposits
of carbon and oil.

g00281694
Illustration 377
SEBU7824-11 255
Maintenance Section
Engine Air Filter Secondary Element - Replace

Do not use paint, a waterproof cover, or plastic as a

protective covering for storage. An airflow restriction
may result. To protect against dirt and damage, wrap
the primary air filter elements in Volatile Corrosion
Inhibited (VCI) paper.

Place the primary air filter element into a box for

storage. For identification, mark the outside of the
box and mark the primary air filter element. Include
the following information:

• Date of cleaning
• Number of cleanings
g00101451
Store the box in a dry location. Illustration 378

3. Remove the secondary filter element.

i02270189
4. Cover the air inlet opening. Clean the inside of
Engine Air Filter Secondary the air cleaner housing.
Element - Replace
5. Remove the cover from the air inlet opening.
SMCS Code: 1054-510
6. Install the new secondary filter element.
NOTICE
7. Install the primary filter element.
Always replace the secondary filter element. Never at-
tempt to reuse the secondary filter element by clean-
8. Install the air cleaner cover and close the latches
ing the element.
securely.
When the primary filter element is replaced, the sec-
9. Close the access door.
ondary filter element should be replaced.

The secondary filter element should also be replaced i01100443

if the restricted Air Filter indicator comes on after the
installation of a clean primary filter element or if the Engine Air Precleaner - Clean
exhaust smoke is still black.
SMCS Code: 1055-070-DJ
1. Open the top access door on the right side of the
Check the engine air precleaner for accumulation of
machine.
trash and dirt.
2. See Operation and Maintenance Manual, “Engine
Air Filter Primary Element - Clean/Replace”.
Remove the air cleaner cover from the air cleaner
housing. Remove the primary filter element from
the air cleaner housing.

g00579001
Illustration 379

1. Loosen the latch and remove the cover from the

precleaner.

2. Clean the cover.

256 SEBU7824-11
Maintenance Section
Engine Crankcase Breather - Clean

3. Clean the precleaner. The precleaner can be 4. Wash the breather in a clean, nonflammable
cleaned with pressure air, pressure water or a solvent.
detergent. When pressure water is used, the
maximum pressure should not exceed 280 kPa 5. Inspect the seal. If the seal is damaged, install a
(40 psi). new seal.

Refer to Operation and Maintenance Manual, 6. Install the O-ring seal and the clean breather.
“General Hazard Information” before you use Tighten the clamp for the breather.
pressure air in order to clean the precleaner.
7. Slide the hose onto the breather. Tighten the hose
Note: Do not clean the precleaner by bumping or clamp.
tapping the precleaner.
8. Close the engine hood. Latch the engine hood.
i02236028

Engine Crankcase Breather -

i02207916

Clean Engine Oil Level - Check

SMCS Code: 1000-535
SMCS Code: 1317-070-DJ

NOTICE
Perform this maintenance with the engine stopped.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
If the crankcase breather is not maintained on a contact the skin.
regular basis, the crankcase breather will become
plugged. A plugged crankcase breather will cause
excessive crankcase pressure that may cause Note: This machine's monitoring system checks fluid
crankshaft seal leakage. levels. However, if the machine is on an incline or the
engine has been stopped only for a short time, the
1. Unlatch the engine hood. Raise the engine hood. engine oil does not return to the crankcase. The fluid
level cannot be properly checked. Park the machine
on level ground and check the oil level after the
engine has been stopped for at least 30 minutes.

The oil level can be checked while the engine is

running. The oil level can also be checked while the
engine is stopped. The recommended procedure is
checking the oil while the engine is stopped.

1. Unlatch the engine hood and raise the engine

hood.

g01127724
Illustration 380
(1) Outlet hose
(2) Hose clamp
(3) Clamp for the breather
(4) Breather cover

2. Loosen the hose clamp (2). Disconnect the outlet

hose (1) from the breather (4).

3. Loosen the clamp for the breather (3). Remove

the breather and the seal. g01114758
Illustration 381
Note: Refer to Operation and Maintenance Manual, (1) Dipstick for the engine oil
“General Hazard Information” for information on (2) Filler plug for the engine oil
containing fluid spillage.
SEBU7824-11 257
Maintenance Section
Engine Oil Sample - Obtain

2. Remove dipstick (1). Wipe the oil off the dipstick i02207897
and reinsert the dipstick.
Engine Oil Sample - Obtain
SMCS Code: 1000-008; 1000; 1348-008;
1348-554-SM; 7542-008; 7542-554-OC, SM

g01100724
Illustration 382

3. Remove the dipstick again. Make sure that the oil

level is between the “ADD” and “FULL” marks on g01114754
the “ENGINE STOPPED” side of the dipstick. Illustration 383

4. If the oil level is too low go to Step 5. Otherwise, Obtain a sample of the engine oil from the
proceed to Step 8. engine oil sampling valve that is located in the
engine compartment. Refer to Special Publication,
Note: Refer to Operation and Maintenance Manual, SEBU6250, “S·O·S Oil Analysis” for information that
“General Hazard Information” for information that pertains to obtaining a sample of the engine oil.
pertains to containing fluid spillage. Refer to Special Publication, PEHP6001, “How To
Take A Good Oil Sample” for more information about
5. Unscrew oil filler plug (2) and remove the oil filler obtaining a sample of the engine oil.
plug.
i02349623
Note: Oil that is badly contaminated or deteriorated
should be replaced early regardless of the change Engine Oil and Filter - Change
interval.
SMCS Code: 1318-510
NOTICE
Operating your engine when the oil level is above the
“FULL” mark could cause your crankshaft to dip into
the oil. The air bubbles created from the crankshaft Hot oil and hot components can cause personal
dipping into the oil reduces the oil's lubricating char- injury. Do not allow hot oil or hot components to
acteristics and could result in the loss of power. contact the skin.

6. Add oil until the oil level is between the “ADD” and Park the machine on a level surface. Stop the engine.
“FULL” marks on the “ENGINE STOPPED” side
of the dipstick. Note: Drain the crankcase while the oil is warm. This
allows waste particles that are suspended in the oil to
7. Clean the filler plug and install the filler plug. drain. As the oil cools, the waste particles will settle
to the bottom of the crankcase. The particles will not
8. Close the engine hood and latch the engine hood. be removed by draining the oil and the particles will
recirculate in the engine lubrication system with the
new oil.
258 SEBU7824-11
Maintenance Section
Engine Oil and Filter - Change

g01173883 g01114767
Illustration 384 Illustration 386
The drain hose for the engine crankcase is located under the rear (1) Dipstick
of the upper structure. (2) Filter
(3) Filler plug
1. Remove the bolts and the washers for the
crankcase drain valve access cover. Remove the 5. Remove the oil filter (2) with a strap type wrench.
access cover.
Note: Dispose of the used oil filter according to local
Note: Refer to Operation and Maintenance Manual, regulations.
“General Hazard Information” for information that
pertains to containing fluid spillage. 6. Inspect the oil filter. See Operation and
Maintenance Manual, “Oil Filter - Inspect”.

7. Clean the filter housing base. Make sure that all of

the old filter gasket is removed.

g01114904
Illustration 385

2. Open the crankcase drain valve. Allow the oil to

drain into a suitable container.
g00101634
Illustration 387
Note: Dispose of drained fluids according to local
regulations. 8. Apply a thin coat of engine oil to the gasket of
the new filter.
3. Close the drain valve.
Note: There are rotation index marks on each engine
4. Open the access door to the engine compartment. oil filter that are spaced 90 degrees or 1/4 of a turn
away from each other. When you tighten engine oil
filters, use the rotation index marks as a guide.

9. Install the engine oil filter hand tight until the seal
of the engine oil filter contacts the base. Note the
position of the index marks on the filter in relation
to a fixed point on the filter base.
SEBU7824-11 259
Maintenance Section
Engine Valve Lash and Fuel Injector Timing - Check

10. Tighten the filter according to the instructions that i00707053

are printed on the filter. Use the index marks as
a guide. Engine Valve Lash and Fuel
11. Unscrew the oil filler plug (3) and remove the oil
Injector Timing - Check
filler plug. SMCS Code: 1105-025; 1209-535; 1290-531-FT
12. Fill the crankcase with new oil. See Operation Refer to the Service Manual for the complete
and Maintenance Manual, “Capacities (Refill)”. procedure for checking the engine valve lash. This
procedure lists the steps for the engine valve lash
13. Clean the oil filler plug and install the oil filler plug. adjustment and the steps in order to check the engine
valve lash.
NOTICE
Do not under fill or overfill engine crankcase with oil. Note: Make sure that a qualified mechanic works on
Either condition can cause engine damage. the injector fuel timing. Special tools and training are
required.

NOTICE Refer to the Service Manual for the complete

Operating your engine when the oil level is above the procedure for checking the injector fuel timing or for
“FULL” mark could cause your crankshaft to dip into adjusting the injector fuel timing.
the oil. The air bubbles created from the crankshaft
dipping into the oil reduces the oil's lubricating char- Note: The correct fuel timing specification is
acteristics and could result in the loss of power. given on the Engine Information Plate. Fuel
timing specifications may differ for distinct engine
applications and/or power ratings.
14. Start the engine and allow the oil to warm. Check
the engine for leaks. Stop the engine.
i00059702
15. Wait for 30 minutes so that the oil can drain back
into the crankcase, before you check the oil. Engine Valve Rotators - Inspect
16. Remove the dipstick (1). Wipe the oil off the SMCS Code: 1109-040
dipstick and reinsert the dipstick.

When inspecting the valve rotators, protective

glasses or face shield and protective clothing
must be worn to prevent being burned by hot oil
spray.

1. Start the engine and run the engine at low idle.

g01100724
Illustration 388

17. Remove the dipstick again. Make sure that the oil
level is between the “ADD” and “FULL” marks on
the “ENGINE STOPPED” side of the dipstick.

18. Close the engine hood and latch the engine hood.

19. Install the crankcase drain valve access cover g00102025

with the bolts and the washers. Illustration 389

2. Watch the top surface on each valve rotator. Each

valve rotator should turn slightly whenever the
cylinder valve closes.
260 SEBU7824-11
Maintenance Section
Ether Starting Aid Cylinder - Replace

If a cylinder valve fails to rotate, consult your i03908954

Caterpillar dealer.
Final Drive Oil - Change
i02203372 SMCS Code: 4050-044-FLV
Ether Starting Aid Cylinder -
Replace
(If Equipped) Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
SMCS Code: 1456-510-CD contact skin.

Refer to Operation and Maintenance, “Fire Prevention

and Explosion Prevention” before you replace the
ether cylinders.

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

the machine.

g00822278
Illustration 391
(1) Oil level plug
(2) Oil drain plug

1. Position one final drive so that oil drain plug (2) is

at the bottom.
g01133009
Illustration 390 Note: Refer to Operation and Maintenance Manual,
(1) Retaining clamps “General Hazard Information” for information on
(2) Ether cylinder Containing Fluid Spillage.
2. Loosen the cylinder retaining clamps (1). Unscrew 2. Remove drain plug (2) and level plug (1). Allow
the empty ether cylinder (2) and remove the empty the oil to drain into a suitable container.
ether cylinder.
3. Clean the plugs and inspect the O-ring seals. If
3. Remove the used seal. Install the new seal. A wear or damage is evident, replace the drain plug,
new seal is provided with each new ether starting the level plug, and/or the O-ring seals.
aid cylinder.
4. Install drain plug (2).
4. Install the new ether starting aid cylinder. Tighten
the ether starting aid cylinder hand tight. Tighten 5. Fill the final drive to the bottom of the opening on
the cylinder retaining clamps securely. level plug (1). See Operation and Maintenance
Manual, “Lubricant Viscosities” and Operation and
5. Close the access door and install the two bolts. Maintenance Manual, “Capacities (Refill) ”.

Note: If the oil fills slowly, the fill hole may be blocked
by the planetary gear. Rotate the final drive in order
to move the planetary gear away from the fill hole.

Note: Overfilling the final drive will cause the seals

on the travel motor to allow hydraulic oil or water
to enter the final drive. The final drive may become
contaminated.

6. Install level plug (1).

SEBU7824-11 261
Maintenance Section
Final Drive Oil Level - Check

7. Perform Step 1 to Step 6 on the other final drive. 4. Add oil through the level plug opening, if
Use a different container for the oil so that the oil necessary. See Operation and Maintenance,
samples from the final drives will be separate. “Lubricant Viscosities”.

8. Completely remove the oil that has spilled onto Note: If the oil fills slowly, the fill hole may be blocked
surfaces. by the planetary gear. Rotate the final drive in order
to move the planetary gear away from the fill hole.
9. Start the engine and allow the final drives to run
through several cycles. Note: Overfilling the final drive will cause the seals
on the travel motor to allow hydraulic oil or water
10. Stop the engine. Check the oil level. to enter the final drive. The final drive may become
contaminated.
11. Check the drained oil for metal chips or for
particles. If there are any chips or particles, consult 5. Clean oil level plug (1). Inspect the O-ring seal.
your Caterpillar dealer. Replace the O-ring seal if the O-ring seal is worn
or damaged.
12. Properly dispose of the drained material. Obey
local regulations for the disposal of the material. 6. Install oil level plug (1).

7. Repeat the procedure for the other final drive.

i03914051

Final Drive Oil Level - Check i03756611

SMCS Code: 4050-535-FLV Final Drive Oil Sample - Obtain

SMCS Code: 4011-008; 4050-008; 4050-SM;
7542-008
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact skin.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact skin.

g00822278
Illustration 392
(1) Oil level plug
(2) Oil drain plug
g00822278
Illustration 393
1. Position one final drive so that oil drain plug (2) is (1) Oil level plug
at the bottom. (2) Oil drain plug

Note: Refer to Operation and Maintenance Manual, 1. Position the final drive so that oil drain plug (2) is
“General Hazard Information” for information on at the bottom.
Containing Fluid Spillage.
Note: Refer to Operation and Maintenance Manual,
2. Remove oil level plug (1). “General Hazard Information” for information on
Containing Fluid Spillage.
3. Check the oil level. The oil should be near the
bottom of the level plug opening. 2. Remove oil level plug (1).
262 SEBU7824-11
Maintenance Section
Fuel System - Prime

3. Obtain a sample of the final drive oil through the 9. Close the engine access doors.
hole for the oil level plug.
i02249792
4. Install oil level plug (1).

Refer to Special Publication, SEBU6250, “Caterpillar

Fuel System Primary Filter
Machine Fluids Recommendations”, “S·O·S Oil (Water Separator) Element -
Analysis” for more information on obtaining a sample
of the final drive oil. For additional information about
Replace
taking an oil sample, refer to Special Publication,
SMCS Code: 1263-510-FQ
PEGJ0047, “How To Take A Good Oil Sample”.

i02249787

Fuel System - Prime Personal injury or death may result from failure to
adhere to the following procedures.
SMCS Code: 1250-548
Fuel leaked or spilled onto hot surfaces or electri-
1. Open the engine access doors. cal components can cause a fire.

Clean up all leaked or spilled fuel. Do not smoke

while working on the fuel system.

Turn the disconnect switch OFF or disconnect the

battery when changing fuel filters.

NOTICE
Do not fill the fuel filters with fuel before installing the
fuel filters. The fuel will not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
ated wear to fuel system parts.

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

g01132436
Illustration 394 the machine. The filter is located to the right of
(1) Vent plug the steps.
(2) Priming pump plunger

2. Loosen vent plug (1) on the filter.

3. Turn priming pump plunger (2) counterclockwise

in order to unlock priming pump plunger (2).
Operate priming pump plunger (2).

4. Tighten vent plug (1) when the fuel flows without

air bubbles.

5. Push in priming pump plunger (2) and tighten

priming pump plunger (2) by hand.

6. Crank the engine. If the engine does not start or if

g01102123
the engine misfires, additional priming is required. Illustration 395
Also if the engine emits smoke, additional priming (1) Filter
is required. (2) Bowl
(3) Drain valve
7. If the engine starts but the engine runs rough,
continue to run the engine at low idle. Run the 2. Turn drain valve (3) counterclockwise in order to
engine at low idle until the engine runs properly. open. The drain valve is located on the bottom
of the water separator.
8. Check the fuel system for leaks. Stop the engine.
SEBU7824-11 263
Maintenance Section
Fuel System Secondary Filter - Replace

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” that pertains to
containing fluid spillage.

3. Drain the water and sediment into a suitable

container.

Note: Dispose of drained fluids and used filters

according to local regulations.

4. Close drain valve (3).

5. Hold the bottom of the filter (1) while you loosen

bowl (2).
g01132438
6. Remove bowl (2). Illustration 396

7. Remove filter (1). Discard filter(1). 2. Remove the fuel filter.

Note: The primary filter is a cartridge type filter. The 3. Inspect the fuel filter for debris by cutting the fuel
filter cannot be reused. filters open.

8. Clean the inside surface of the filter head and of Note: The fuel filters are cartridge type filters. The
bowl (2). filters cannot be reused.

9. Inspect the O-ring on bowl (2). Also inspect the Note: Dispose of used filters and used fluids
seal on the filter head. Replace these seals if the according to local regulations.
seals are worn or damaged.
4. Clean the filter mounting base. Make sure that all
10. Lubricate the seal of the new element with clean of the old seal is removed.
diesel fuel.

11. Install the new filter. Tighten the filter by hand

until the seal contacts the filter base. Additionally
tighten the filter by 1/3 to 1/2 turn onto filter base.

12. Install bowl (2).

13. Close the access door.

i02249791

Fuel System Secondary Filter -

Replace Illustration 397
g00101634

SMCS Code: 1261-510

5. Lubricate the seal of the new filter with clean
diesel fuel.
NOTICE
Turn the disconnect switch OFF or disconnect the bat- 6. Install the new filter by hand. Additionally tighten
tery when changing fuel filters. the filter by 3/4 of a turn, after the gasket contacts
the filter base.
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel Every new filter has four rotation index marks.
system parts. Each mark indicates 1/4 turn. Use these rotation
index marks as a guide for proper tightening.
1. Open the engine access doors.
7. Prime the fuel system. Refer to Operation and
Maintenance, “Fuel System - Prime”.

8. Close the engine access doors.

264 SEBU7824-11
Maintenance Section
Fuel System Water Separator - Drain

i02249789 i01589598

Fuel System Water Separator Fuel Tank Cap and Strainer -

- Drain Clean
SMCS Code: 1263 SMCS Code: 1273-070-STR

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

the machine. The filter is located to the right of
the steps.

g00824193
Illustration 399

1. Remove the fuel cap.

Illustration 398
g01101164 2. Inspect seal (4) for damage. Replace the seal, if
necessary.
2. If water is present, drain the water from the bowl.
3. Remove screws (1), filter assembly (2), drain
3. Turn the drain valve counterclockwise in order to valve (3) and the gaskets.
open.

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information that
pertains to containing fluid spillage.

4. Drain the water and drain the sediment into a

suitable container.

Note: Dispose of drained fluids according to local

regulations.

5. Close the drain valve.

6. Close the access door. g00824196

Illustration 400

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information on
Containing Fluid Spillage.

4. Remove the strainer that is located in the filler

opening.

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

nonflammable solvent.

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

valve (3), filter assembly (2), and screws (1).

7. Install the strainer into the filler opening.

SEBU7824-11 265
Maintenance Section
Fuel Tank Water and Sediment - Drain

8. Install the fuel tank cap. The fuse panel is located on the circuit breaker panel.
Open the access cover for fuse access.
i02203465
Fuses – Fuses protect the electrical
Fuel Tank Water and Sediment system from damage that is caused by
overloaded circuits. Change a fuse if the
- Drain element separates. If the element of a new fuse
separates, check the circuit and/or repair the circuit.
SMCS Code: 1273-543

The fuel tank drain valve is located on the side of the NOTICE
machine under the fuel tank. Always replace fuses with the same type and capacity
fuse that was removed. Otherwise, electrical damage
could result.

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

Contact your Caterpillar dealer.

To replace a fuse, use the puller that is stored in the

fuse panel. The following spare fuses are stored in
the fuse panel: three fuses of 5 Amperes, four fuses
of 10 Amperes, and two fuses of 15 Amperes.
g01043694
Illustration 401 The following list identifies the circuits that are
protected by each fuse. The amperage for each fuse
Note: Refer to Operation and Maintenance Manual, is included with each circuit.
“General Hazard Information” for information on
containing fluid spillage.

1. Open the drain valve by turning the valve

counterclockwise. Allow the water and the
sediment to drain into a suitable container.

Note: Dispose of drained fluids according to local

regulations.

2. Close the drain valve by turning the valve

clockwise.

Fill the Fuel Tank

You can now add fuel to the fuel tank, if necessary.
Remove the fuel tank cap and pump fuel through the
opening.

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

i03293703

Fuses - Replace
SMCS Code: 1417-510
g01677755
Illustration 402
Open the access door on the left side of the machine.
(1) Spare – 5 Amp
266 SEBU7824-11
Maintenance Section
Fuses - Replace

(2) Spare – 5 Amp (32) Engine Control Module (ECM) – 15 Amp

(3) Spare – 5 Amp (33) Boom's Left Light – 10 Amp

(4) Spare – 10 Amp (34) Boom's Right Light – 10 Amp

(5) Spare – 15 Amp (35) Beacon – 10 Amp

(6) Spare – 15 Amp (36) Air Suspension Seat – 10 Amp

(7) Spare – 10 Amp (37) Spare – 10 Amp

(8) Air Conditioner 1 – 10 Amp (38) Spare – 10 Amp

(9) Cab Light – 10 Amp

(10) Horn – 10 Amp

(11) Timer Relay – 5 Amp

(12) Machine Control Module 1 – 15 Amp

(13) Product Link – 5 Amp

(14) Engine Start Switch – 10 Amp

(15) Machine Control Module 2 – 15 Amp

(16) Cab Dome Light and Radio Memory – 5 Amp

(17) Heater and Air Conditioner Blower Fan – 15

Amp

(18) Electric Refueling Pump – 30 Amp

(19) Window Wiper and Window Washer – 15 Amp

(20) Chassis Light – 10 Amp

(21) Seat Heater – 5 Amp

(22) Cigar Lighter – 10 Amp g01677759

Illustration 403

(23) Radio – 5 Amp (39) Chassis Lamp – Relay

(24) Automatic Lubrication – 10 Amp (40) Cab Lamp – Relay

(25) 12 Volt 7 Amp Converter – 10 Amp (41) Horn – Relay

(26) 12 Volt 7 Amp Converter – 10 Amp (42) Hydraulic Lock Solenoid – Relay

(27) Air Conditioner 2 – 15 Amp (43) Neutral Start – Relay

(28) Auxiliary 1 – 10 Amp (44) Ether – Relay

(29) Auxiliary 2 – 10 Amp (45) Boom Light 1 – Relay

(30) Auxiliary 3 – 10 Amp (46) Boom Light 2 – Relay

(31) Attachment Solenoid – 5 Amp

SEBU7824-11 267
Maintenance Section
Hydraulic System Filter Element (Fine Filtration) - Replace

i02269550

Hydraulic System Filter

Element (Fine Filtration) -
Replace
(If Equipped)
SMCS Code: 5068-510

The fine filtration filter extends the life of the hydraulic

oil. This filter should be used when biodegradable
hydraulic oil is used in the hydraulic system in order
to absorb the water that may be present.

g00607171
Illustration 405
(1) Bolt
(2) Filter cover
(3) Filter element
(4) Filter case
(A) Band

3. Remove bolt (1) and filter cover (2).

g01137313
Illustration 404
4. Pull out filter element (3) from filter case (4) by
gripping two bands (A).
Replace the filter when the pressure gauge indicates
a pressure of “0.5 Mpa” or more. The filter should be
replaced when this pressure is attained regardless of
the maintenance interval.

1. Park the machine on level ground.

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

the machine.

g00607173
Illustration 406
(2) Filter cover
(5) Packing

5. Inspect packing (5) on the filter cover (2). Replace

the packing if the packing is worn or damaged.

6. Install the new filter by reversing Step 1 through

Step 5.

7. Tighten the bolt to a torque of 59 ± 2.4 N·m

(43.52 ± 1.77 lb ft).

8. Close the access door.

268 SEBU7824-11
Maintenance Section
Hydraulic System Oil - Change

i03292706

Hydraulic System Oil - Change

SMCS Code: 5056-044

Cat HYDO Oil Change Interval

The standard Cat HYDO oil change interval is every
2000 service hours or 1 year.

A 4000 service hour or 2 year maintenance interval

for hydraulic oil (change) is available. The extended
interval requires S·O·S monitoring of the hydraulic
oil. The interval for S·O·S monitoring is every 500 g01137376
Illustration 407
hours. The maintenance interval for the hydraulic oil
filter is not changed.
3. Relieve the internal pressure from the hydraulic
tank by loosening the fill/vent plug. After the
Machines with hammers are not included in the
pressure is relieved, remove the fill/vent plug.
4000 service hour or 2 year maintenance interval.
Machines with hammers must use the intervals that
are listed in the Maintenance Interval Schedule.
Machines that are used in severe conditions are
not included in the 4000 service hour or 2 year
maintenance interval. Machines that are used
in severe conditions must use the interval in the
Maintenance Interval Schedule.

Cat HYDO Advanced 10 Oil Change

Interval
The standard Cat HYDO Advanced 10 oil change
interval is every 3000 service hours or 18 months.
g01137581
Illustration 408
A 6000 service hour or 3 year maintenance interval
for hydraulic oil (change) is available. The extended
4. Remove the two access covers that are located
interval requires S·O·S monitoring of the hydraulic
under the hydraulic tank. This will allow access to
oil. The interval for S·O·S monitoring is every 500
the drain valve and the pipe.
hours. The maintenance interval for the hydraulic oil
filter is not changed.

Machines with hammers are not included in the

6000 service hour or 3 year maintenance interval.
Machines with hammers must use the intervals that
are listed in the Maintenance Interval Schedule.
Machines that are used in severe conditions are
not included in the 6000 service hour or 3 year
maintenance interval. Machines that are used
in severe conditions must use the interval in the
Maintenance Interval Schedule.

Drain the Oil

g01137579
1. Park the machine in the servicing position on level Illustration 409
ground.
Note: Refer to Operation and Maintenance Manual,
2. Clean the top of the hydraulic tank thoroughly in “General Hazard Information” for information that
order to keep dirt out of the hydraulic tank. pertains to containing fluid spillage.

5. Remove plug (1).

SEBU7824-11 269
Maintenance Section
Hydraulic System Oil - Change

14. Clean the plug. Install the plug and the O-ring into
the drain port.

g01137582
Illustration 412

15. Remove the cover to the hydraulic tank screen.

g01137580
Illustration 410
(2) Drain plug
(3) Pipe Nipple
(4) Tube

6. Install a pipe nipple (3) with a clear plastic tube (4)

into the hole on the bottom of the hydraulic tank.

7. Loosen drain plug (2) in order to drain the oil.

8. Drain the oil into a suitable container.

9. After the oil has been drained, tighten drain plug

(7) to a torque of 110 ± 15 N·m (81 ± 11 lb ft).

10. Remove the pipe nipple.

11. Clean plug (1) and install the plug. Tighten the
plug to a torque of 75 ± 5 N·m (55 ± 48 lb ft).

g01137588
Illustration 413
(5) Spring
(6) Screen

Note: Do not allow spring (5) to fall back into the tank.

16. Remove spring (5) and screen (6).

Note: Refer to Operation and Maintenance, “General

Hazard Information” for information on containing
fluid spillage.

17. Wash the screen in a clean nonflammable solvent.

g01137392 Allow the screen to dry. Inspect the screen.
Illustration 411
Replace the screen, if the screen is damaged.
12. Remove the plug from the tube. Allow the oil to
drain into a container.

13. Inspect the O-ring. Replace the O-ring if wear or

damage is evident.
270 SEBU7824-11
Maintenance Section
Hydraulic System Oil - Change

18. There is an O-ring seal on the bottom of the

screen. There is also an O-ring seal on the
hydraulic tank around the opening for the screen.
Inspect the O-ring seals. Replace the O-ring seals
if wear or damage is evident.

19. Install the screen and the spring. Then install the
cover.

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

Service the Hydraulic System

Filters g01137398
Illustration 414
Note: The hydraulic oil system must be empty when
the filters are being serviced. Service the filters b. Slowly loosen the vent plug on top of the case
before refilling the machine with hydraulic oil. drain filter until hydraulic oil flows out of the
vent plug.
Note: Dispose of used filters and used fluids
according to local regulations. c. After oil flows out of the vent plug without
any air bubbles, tighten the vent plug. This
Refer to the following topics in order to service the indicates that the air has been purged from the
hydraulic system filters: drain lines for the main pump and the drain line
for the swing pump. Tighten the vent plug to a
• Operation and Maintenance Manual, “Hydraulic torque of 11 ± 1 N·m (97 ± 9 lb in).
System Filter Element (Fine Filtration) - Replace
(If Equipped)” d. Stop the engine.

• Operation and Maintenance Manual, “Hydraulic 3. Start the engine. Operate the engine at idling
System Oil Filter (Return) - Replace” speed for five minutes.

• Operation and Maintenance Manual, “Hydraulic 4. Operate the joysticks in order to circulate the
System Oil Filter (Case Drain) - Replace” hydraulic oil. Return the machine to the servicing
position. Stop the engine.
• Operation and Maintenance Manual, “Hydraulic
System Oil Filter (Pilot) - Replace”

Fill the Hydraulic Tank

1. Fill the hydraulic system oil tank. Refer to
Operation and Maintenance Manual, “Capacities
(Refill)”.

2. Inspect the O-ring seal on the filler plug for

damage. Replace the O-ring, if necessary. Clean
the filler plug. Install the filler plug.

Note: Make no attempt to start the engine until the

pump has been filled with hydraulic oil. Serious Illustration 415
g01137399
damage to the hydraulic components can result. (A) High temperature range
(B) Low temperature range
When the hydraulic oil has been replaced, the air
must be removed from the hydraulic oil system. 5. Maintain the oil level between the marks on the
To remove the air from the hydraulic oil system, sight gauge in the appropriate temperature range.
follow Step 2.a through Step 2.d.

a. Start the engine.

SEBU7824-11 271
Maintenance Section
Hydraulic System Oil Filter (Case Drain) - Replace

i02270478 7. After replacing any hydraulic filter, the air must

be purged from each filter. Perform Step 7.a
Hydraulic System Oil Filter through Step 7.c in order to purge the air from the
(Case Drain) - Replace hydraulic system.

SMCS Code: 5068-510; 5091-510 a. Start the engine.

1. Open the right front access door. b. Slowly loosen the vent plug on top of the filter
until oil flows out of the vent plug.
2. Clean the area in order to keep dirt out of the filter
base. c. Tighten the vent plug.

8. Drive the machine slowly for 10 to 15 minutes.

Move each cylinder evenly through several cycles.

9. Return the machine to the servicing position.

Check the machine for oil leaks.

10. Stop the engine.

g01137416
Illustration 416

3. Slowly loosen vent plug (1) that is on top of the

filter in order to release the pressure from the filter.
Tighten the vent plug.

4. Remove the used case drain filter (2) from the

filter base.
g01137399
Illustration 418
Note: This element is a cartridge type filter. The (A) High temperature range
element cannot be reused. (B) Low temperature range

Note: Dispose of used filters according to local 11. Maintain the oil level in the low temperature range
regulations. for a cold machine. Maintain the oil level in the
high temperature range for a machine that is at a
5. Clean the filter base. normal operating temperature.

g00101502 g01137376
Illustration 417 Illustration 419

6. Coat the seal of a new case drain filter with clean 12. Slowly loosen the fill/vent plug in order to relieve
hydraulic oil. Install the new case drain filter in the any pressure. Remove the fill/vent plug in order
filter base. Tighten the case drain filter hand tight. to add oil, if necessary.
272 SEBU7824-11
Maintenance Section
Hydraulic System Oil Filter (Pilot) - Replace

13. Clean the fill/vent plug. Install the fill/vent plug. 6. Close the access door.

7. After replacing any hydraulic filter, the air must

i02270497
be purged from each filter. Perform Step 7.a
Hydraulic System Oil Filter through Step 7.c in order to purge the air from the
hydraulic system.
(Pilot) - Replace
a. Start the engine.
SMCS Code: 5068-510; 5068-510-PS; 5092-510
b. Slowly loosen the vent plugs on top of each
1. Open the lower right rear access door. filter until oil flows out of the vent plugs.

c. Tighten the vent plugs.

8. Drive the machine slowly for 10 to 15 minutes.

Move each cylinder evenly through several cycles.

9. Return the machine to the servicing position.

Check the machine for oil leaks.

10. Stop the engine.

g01137437
Illustration 420

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

base.

3. Remove the used pilot filter element from the filter

base.

Note: This element is a cartridge type filter. The

element cannot be reused.
g01137399
Illustration 422
Note: Dispose of used filters according to local (A) High temperature range
regulations. (B) Low temperature range

4. Clean the filter base. 11. Maintain the oil level in the low temperature range
for a cold machine. Maintain the oil level in the
high temperature range for a machine that is at a
normal operating temperature.

g00101502
Illustration 421

5. Coat the seal of a new pilot filter with clean

hydraulic oil. Install the new pilot filter in the filter Illustration 423
g01137376
base. Tighten the pilot filter hand tight.
SEBU7824-11 273
Maintenance Section
Hydraulic System Oil Filter (Return) - Replace

12. Slowly loosen the fill/vent plug in order to relieve 2. Remove the filter cartridge. Perform Step 2.a
any pressure. Remove the fill/vent plug in order through Step 2.f in order to remove the filter
to add oil, if necessary. cartridge.

13. Clean the fill/vent plug. Install the fill/vent plug.

i02270506

Hydraulic System Oil Filter

(Return) - Replace
SMCS Code: 5068-510-RJ

The return filter is a cartridge type filter. By using a

cartridge type filter, the amount of foreign material
that enters the hydraulic system is reduced when the
filter element is replaced.
g00102211
Illustration 426
Note: If the display shows that the hydraulic return (1) Bolts
filter is plugged, push the reset switch. Run the (2) Washers
machine on level ground for approximately 10 (3) Cover
(4) Plug
seconds. If the error is still present, inspect the filter
(5) Filter cartridge
and replace the filter, if necessary.
a. Remove bolts (1), washers (2), and cover (3).

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information on
containing fluid spillage.

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

pressure in filter cartridge (5).

g01137376
Illustration 424

1. Loosen the filler plug in order to relieve the

hydraulic tank pressure. Tighten the filler plug
after the hydraulic tank pressure is relieved.

g00102212
Illustration 427
(5) Filter cartridge
(6) Filter case
(A) Guide

c. Pull up the handle at the top of filter cartridge

(5) until the filter cartridge contacts guide (A)
on filter case (6).

g01137449
Illustration 425
274 SEBU7824-11
Maintenance Section
Hydraulic System Oil Filter (Return) - Replace

g00102214 g00104507
Illustration 428 Illustration 430
(4) Plug
d. Turn the filter cartridge counterclockwise by (8) Plate
180 degrees in order to align the projection of (18) O-ring
the filter cartridge with the notch of the filter
case. Pull out the filter cartridge. a. Make sure that plug (4) is removed. Make sure
that all of O-ring (18) is removed from plate (8).

g00102219
Illustration 429
g00104508
Illustration 431
(7) O-ring
(8) Plate
(9) Spiral retaining ring
e. Inspect the cover and O-ring (7). If either part
is damaged, replace the part.
b. Use a flat screwdriver in order to remove spiral
f. Inspect the filter cartridge for debris and retaining ring (9).
for damage. If necessary, replace the filter
cartridge.

g. Repeat Step 2.a through Step 2.f for the other

filter groups.

3. Remove the filter element. Perform Step 3.a

through Step 3.f in order to remove the filter
element.

g00104510
Illustration 432
(8) Plate
(10) Shell
(11) O-ring
(12) Filter element
SEBU7824-11 275
Maintenance Section
Hydraulic System Oil Filter (Return) - Replace

c. Hold the filter cartridge with one hand. Grasp a. Apply spray type oil to the inside of shell (10) in
the grip of plate (8) with your other hand. Lift order to prevent rust.
plate (8) in order to separate plate (8) from the
filter cartridge. b. Apply grease to a new O-ring (11).

d. Remove O-ring (11) from plate (8). c. Plate (8) will contact the inside of shell (10).
Apply grease to this point.
e. Lift filter element (12) from shell (10).
d. Apply grease to O-rings inside ports (19) at the
f. Pour the remaining oil into a suitable container. bottom of shell (10).

Note: Dispose of used oil according to local e. Install new Pads (14). Tighten the screws to a
regulations. torque of 0.4 N·m (3.5 lb in).

g. Repeat Step 3.a through Step 3.f for the other f. Apply spray type oil into the clearance between
filter groups. shell (10) and slide plate (13).

4. Clean the shell of the filter cartridge. Perform Step

4.a through Step 4.d in order to clean the shell of
the filter cartridge.

g00104512
Illustration 434
(8) Plate
(10) Shell
(16) Boss
g00104511 (17) Notch
Illustration 433
(13) Slide plate
(14) Pads
g. Turn over shell (10). Apply grease to the two
(15) Screws O-rings on new element (12). Install element
(19) Port (12) into shell (10).

a. Turn shell (10) upside-down. h. Move boss (16) in alignment with notch (17).
Install plate (8) into shell (10).
b. Remove screws (15).
i. Install spiral retaining ring (9) into the groove
c. Remove Pads (14) from slide plate (13). in shell (10).

d. Wash the following parts in a clean j. Apply grease to new O-ring (18). Install O-ring
nonflammable solvent: plug (4), plate (8), spiral (18) on plug (4).
retaining ring (9), shell (10), and Pads (14). Dry
the parts. k. Install plug (4) into plate (8).

e. Repeat Step 4.a through Step 4.d for the other l. Repeat Step 5.a through Step 5.k for the other
filter groups. filter groups.

5. Install the filter elements. Perform Step 5.a through 6. Install the filter cartridge. Perform Step 6.a through
Step 5.k in order to install the filter elements. Step 6.e in order to install the filter cartridge.

Note: Consult a Caterpillar dealer for the Service Kit

that is needed to install the filter element and the
filter cartridge.
276 SEBU7824-11
Maintenance Section
Hydraulic System Oil Filter (Return) - Replace

g00102220 g00102222
Illustration 435 Illustration 437
(B) Port (F) O-rings
(C) Slide plate
c. Check that O-rings (F) have been installed and
a. Check that ports (B) at the bottom of the filter that oil has been applied to O-rings (F).
case are closed.

Note: If the ports are open, rotate slide plate (C)

counterclockwise to the stopper in order to fully
close the ports. When the ports are fully closed, any
remaining oil in the filter case should be completely
removed.

g00102225
Illustration 438
(1) Bolts

d. Install the filter cartridge into the filter case.

Turn the filter cartridge clockwise by 180
degrees and push down the filter cartridge
g00102221 when the filter cartridge contacts guide (A).
Illustration 436
(E) Slide plate
(D) Port
e. Install plug (4), cover (3), washers (2), and bolts
(1). Tighten bolts (1) to a torque of 29 ± 5 N·m
(22 ± 4 lb ft).
b. Check that ports (D) of the filter cartridge are
fully closed.
f. Repeat Step 6.a through Step 6.e for the other
filter groups.
Note: The filter cartridge cannot be installed unless
the ports are fully closed. If the ports are open, rotate
slide plate (E) counterclockwise to the stopper in
order to fully close the ports.
SEBU7824-11 277
Maintenance Section
Hydraulic System Oil Level - Check

i02270531 4. Check the O-ring seal of the fill/vent plug. Replace

the O-ring seal if the O-ring seal is damaged.
Hydraulic System Oil Level -
Check 5. Clean the fill/vent plug and install the fill/vent plug.

SMCS Code: 5050-535 i02207737

NOTICE Hydraulic System Oil Sample

Never remove the fill/vent plug from the hydraulic tank
if the oil is hot.
- Obtain
SMCS Code: 5050-008-OC; 5095-008; 5095-SM;
Air can enter the system and cause pump damage. 7542-008; 7542

1. Park the machine on level ground. Place the

machine in the servicing position.

g01114987
Illustration 441

The hydraulic oil sampling valve is in the rear access

Illustration 439
g01137399 compartment on the right side of the machine. Obtain
(A) High temperature range
a sample of the hydraulic oil from the hydraulic
(B) Low temperature range oil sampling valve. Refer to Special Publication,
SEBU6250, “S·O·S Oil Analysis” for information that
2. For a cold machine, maintain the hydraulic oil level pertains to obtaining a sample of the hydraulic oil.
in the low temperature range. For a machine that Refer to Special Publication, PEHP6001, “How To
is at normal operating temperature, maintain the Take A Good Oil Sample” for more information about
hydraulic oil level in the high temperature range. obtaining a sample of the hydraulic oil.

i02270539

Hydraulic Tank Screen - Clean

SMCS Code: 5056-070-Z3

1. Park the machine in the servicing position on level

ground.

2. Clean the top of the hydraulic tank thoroughly in

order to keep dirt out of the hydraulic tank.

g01137376
Illustration 440

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information on
containing fluid spillage.

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

any pressure. Add oil, if necessary.
278 SEBU7824-11
Maintenance Section
Hydraulic Tank Screen - Clean

g01137376
Illustration 442

3. Relieve the internal pressure from the hydraulic

tank by loosening the fill/vent plug. After the
pressure is relieved, remove the fill/vent plug.

g01137590
Illustration 444
(1) Spring
(2) Screen

Note: Do not allow spring (1) to fall back into the tank.

5. Remove spring (1) and screen (2).

Note: Refer to Operation and Maintenance, “General

Hazard Information” for information on containing
fluid spillage.

6. Wash the screen in a clean nonflammable solvent.

Illustration 443
g01137582 Allow the screen to dry. Inspect the screen.
Replace the screen, if the screen is damaged.
4. Remove the cover to the hydraulic tank screen.
7. There is an O-ring seal on the bottom of the
screen. There is also an O-ring seal on the
hydraulic tank around the opening for the screen.
Inspect the O-ring seals. Replace the O-ring seals
if wear or damage is evident.

8. Install the screen and the spring. Then install the

cover.

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

9. Inspect the O-ring seal on the filler plug for

damage. Replace the O-ring, if necessary. Clean
the filler plug. Install the filler plug.

10. Install the cover plate on top of the hydraulic tank.

SEBU7824-11 279
Maintenance Section
Indicators and Gauges - Test

i02116248 i01909798

Indicators and Gauges - Test Oil Filter - Inspect

SMCS Code: 7450-081; 7490-081 SMCS Code: 1308-507; 5068-507

Inspect a Used Filter for Debris

g01077750
Illustration 445

1. Look for broken lenses on the gauges, broken g00100013

Illustration 446
indicator lights, broken switches, and other broken
components in the cab. The element is shown with debris.

2. Start the engine. Use a filter cutter in order to cut the filter element
open. Spread apart the pleats and inspect the
3. Look for inoperative gauges. element for metal and for other debris. An excessive
amount of debris in the filter element can indicate a
4. Turn on all machine lights. Check for proper possible failure.
operation.
If metals are found in the filter element, a magnet can
5. Move the machine forward. Release the travel be used to differentiate between ferrous metals and
levers and the travel pedals. The machine should nonferrous metals.
stop.
Ferrous metals can indicate wear on steel parts and
6. Stop the engine. on cast iron parts.

7. Make any repairs that are required before Nonferrous metals can indicate wear on the
operating the machine. aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.

Small amounts of debris may be found in the filter

element. This could be caused by friction and by
normal wear. Consult your authorized dealer in order
to arrange for further analysis if an excessive amount
of debris is found.

Using an oil filter element that is not recommended

can result in severe engine damage to engine
bearings, to the crankshaft, and to other parts. This
can result in larger particles in unfiltered oil. The
particles could enter the lubricating system and the
particles could cause damage.
280 SEBU7824-11
Maintenance Section
Radiator Core - Clean

i02270193 i02723802

Radiator Core - Clean Receiver Dryer (Refrigerant) -

SMCS Code: 1353-070 Replace
SMCS Code: 7322-510
1. Open the rear access panel on the left side of
the machine.

Personal injury can result from contact with refrig-

erant.

Contact with refrigerant can cause frost bite. Keep

face and hands away to help prevent injury.

Protective goggles must always be worn when re-

frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant.

Always use precaution when a fitting is removed.

Slowly loosen the fitting. If the system is still un-
g01137326
der pressure, release it slowly in a well ventilated
Illustration 447 area.
2. Check the radiator fins for debris. Personal injury or death can result from inhaling
refrigerant through a lit cigarette.
3. Remove dust and debris from the radiator fins.
Inhaling air conditioner refrigerant gas through a
Refer to Operation and Maintenance, “General lit cigarette or other smoking method or inhaling
Hazard Information” for the proper safety fumes released from a flame contacting air con-
precautions that should be followed before ditioner refrigerant gas, can cause bodily harm or
compressed air is used. death.
Compressed air is preferred, but high pressure Do not smoke when servicing air conditioners or
water or steam can be used to remove dust and wherever refrigerant gas may be present.
general debris from a radiator. Clean the radiator
according to the condition of the radiator. Use a certified recovery and recycling cart to prop-
erly remove the refrigerant from the air condition-
Refer to Special Publication, SEBD0518, ing system.
“Know Your Cooling System” for more detailed
information about cleaning radiator fins.
NOTICE
4. Close the access door and install the bolts. If the refrigerant system has been open to the outside
air (without being plugged) for more than 30 minutes,
the receiver-dryer must be replaced. Moisture will en-
ter an open refrigerant system and cause corrosion
which will lead to component failure.

Refer to Service Manual, SENR5664, “Air

Conditioning and Heating System with R-134a
Refrigerant for All Caterpillar Machines” for the proper
procedure to change the receiver-dryer assembly
and for the procedure to reclaim the refrigerant gas.
SEBU7824-11 281
Maintenance Section
Seat Belt - Inspect

i02429589 i02429594

Seat Belt - Inspect Seat Belt - Replace

SMCS Code: 7327-040 SMCS Code: 7327-510

Always check the condition of the seat belt and the Within three years of the date of installation or within
condition of the seat belt mounting hardware before five years of the date of manufacture, replace the
you operate the machine. Replace any parts that are seat belt . Replace the seat belt at the date which
damaged or worn before you operate the machine. occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.

g00932801
Illustration 448 g01152685
Illustration 449
Typical example
(1) Date of installation (retractor)
(2) Date of installation (buckle)
Check the seat belt mounting hardware (1) for wear (3) Date of manufacture (tag) (fully extended web)
or for damage. Replace any mounting hardware that (4) Date of manufacture (underside) (buckle)
is worn or damaged. Make sure that the mounting
bolts are tight. Consult your Caterpillar dealer for the replacement of
the seat belt and the mounting hardware.
Check buckle (2) for wear or for damage. If the buckle
is worn or damaged, replace the seat belt. If your machine is equipped with a seat belt
extension, also perform this replacement procedure
Inspect the seat belt (3) for webbing that is worn or for the seat belt extension.
frayed. Replace the seat belt if the seat belt is worn
or frayed.
i03867596

Consult your Caterpillar dealer for the replacement of Swing Bearing - Lubricate
the seat belt and the mounting hardware.
SMCS Code: 7063-086
Note: Within three years of the date of installation or
within five years of the date of manufacture, replace Note: Caterpillar recommends the use of
the seat belt. Replace the seat belt at the date which multipurpose lithium grease NLGI Grade 2 for
occurs first. A date label for determining the age of lubricating the swing bearing. Refer to Special
the seat belt is attached to the seat belt, the seat belt Publication, SEBU6250, “Caterpillar Machine
buckle, and the seat belt retractor. Fluids Recommendations” for more information on
multipurpose lithium grease.
If your machine is equipped with a seat belt
extension, also perform this inspection procedure for Note: Do not overgrease the swing bearings. Do not
the seat belt extension. grease more than the recommended maintenance
interval. Refer to Operation and Maintenance
Manual, “Maintenance Interval Schedule” for more
information.

Wipe the fittings before you lubricate the swing

bearings.
282 SEBU7824-11
Maintenance Section
Swing Drive Oil - Change

i02270209

Swing Drive Oil - Change

SMCS Code: 5459-044

Drain the Swing Drives

g02110713
Illustration 450

The swing bearings are under the base of the boom.

g01137435
Illustration 452
This swing drive is located next to the cab under the boom.

1. Remove drain hose (1) from the frame. Face the

end of the hose toward the container.

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information that
pertains to containing fluid spillage.

Illustration 451
g01106319 2. Loosen the drain valve (2). Drain the oil into a
suitable container.
Apply lubricant through the fittings until the lubricant
overflows the bearing seals. Note: Dispose of drained fluids according to local
regulations.

3. Tighten the drain valve.

4. Return the end of the drain hose to the frame.

Make sure that the end of the hose is facing
upward.

g01137433
Illustration 453
SEBU7824-11 283
Maintenance Section
Swing Drive Oil Level - Check

5. Remove the access cover that is located under

the machine, near the swing gear.

g01137328
Illustration 456

Illustration 454
g01137436 1. Remove the dipstick.

6. Pull out the end of the drain hose (1) from the 2. Add the specified quantity of oil through the
upper frame. Face the end of the hose toward dipstick tube. See Operation and Maintenance,
the container. “Capacities (Refill)”.

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information that
pertains to containing fluid spillage.

7. Reach through the access hole and open the drain

valve (2). Drain the oil into a suitable container.

Note: Dispose of drained fluids according to local

regulations.

8. Tighten the drain valve.

9. Return the end of the drain hose to the upper

frame. Make sure that the end of the hose is g01137329
facing upward. Illustration 457

10. Install the access cover. 3. Make sure that the oil level is maintained below
the “H” mark on the dipstick.
Refill the Swing Drives 4. Check the oil that has been drained for metal chips
or metal particles. Consult your Caterpillar dealer
Note: Perform this procedure for each swing drive. if any metal chips or metal particles are found.

Note: Dispose of drained materials according to local

regulations.

i02270202

Swing Drive Oil Level - Check

SMCS Code: 5459-535-FLV

The dipstick for the swing drive oil is on the swing

drive at the base of the boom.

Note: There are two swing drives that are located

Illustration 455
g01137327 under the base of the boom. Perform the same
procedure for both swing drives.
284 SEBU7824-11
Maintenance Section
Swing Drive Oil Sample - Obtain

5. Reinsert the dipstick.

i02270208

Swing Drive Oil Sample -

Obtain
SMCS Code: 5459-008; 5459-008-OC;
5459-554-OC; 5459-OC; 7542-008

g01137327
Illustration 458

g01137327
Illustration 461

g01137328
Illustration 459

1. Remove the dipstick.

g01137328
Illustration 462

Obtain an oil sample of the swing drive oil through the

opening for the dipstick. Refer to Special Publication,
SEBU6250, “S·O·S Oil Analysis” for information
that pertains to obtaining an oil sample from the
swing drive housing. Refer to Special Publication,
PEHP6001, “How To Take A Good Oil Sample” for
g01137329
Illustration 460 more information about obtaining an oil sample from
the swing drive housing.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.

2. Check the dipstick. Maintain the oil level below

the “H” mark on the dipstick. Add oil through the
dipstick tube, if necessary.

3. Insert the dipstick.

4. Check the dipstick again.

SEBU7824-11 285
Maintenance Section
Swing Gear - Lubricate

i02803855 3. Check the level of the grease. The grease should

be evenly distributed on the floor of the pan.
Swing Gear - Lubricate
SMCS Code: 7063-086

NOTICE
Improper lubrication can cause damage to machine
components.

To avoid damage, make sure that the proper amount

of grease is applied to the swing drive.

When the amount of grease in the compartment be-

comes too large, the agitation loss becomes large,
thereby accelerating grease deterioration.
g00101653
Grease deterioration can cause damage to the pinion Illustration 465
gear of the swing drive and swing internal gear. (5) Plug
(6) O-ring
Not enough grease will result in poor gear lubrication.
4. Check for contamination and for discolored
grease. Remove plug (5) in order to allow the
water to drain. When you reinstall plug (5), inspect
O-ring seal (6). Replace the O-ring seal if damage
is evident.

5. If the contamination level is very high, contact

your Caterpillar dealer.

g00845075
Illustration 463
The access cover is located in the battery compartment.

g00837653
Illustration 466

6. Raise the boom. Turn the upper structure. Lower

the bucket to the ground.

7. Repeat Step 3 at every 30 degrees in 12 places.

Add grease, as needed.

g00837649
Illustration 464

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

(3) and gasket (4).

2. Inspect gasket (4). Replace the gasket if damage

is evident.
286 SEBU7824-11
Maintenance Section
Swing Gear - Lubricate

i03299265 3. Check the level of the grease. The grease should

be evenly distributed on the floor of the pan.
Swing Gear - Lubricate
Refer to Operation and Maintenance Manual,
SMCS Code: 7063-086 “Capacities (Refill)” for the capacity of the swing
gear.
NOTICE
Improper lubrication can cause damage to machine Add grease, as needed. Remove grease, as
components. needed. Too much grease will result in the
deterioration of the grease that is caused by
To avoid damage, make sure that the proper amount excessive movement of the grease. Too little
of grease is applied to the swing drive. grease will result in poor lubrication of the swing
gear.
When the amount of grease in the compartment be-
comes too large, the agitation loss becomes large,
thereby accelerating grease deterioration.

Grease deterioration can cause damage to the pinion

gear of the swing drive and swing internal gear.

Not enough grease will result in poor gear lubrication.

g00101653
Illustration 469

4. Check for contamination and for discolored

grease.

5. If the grease is contaminated or discolored with

water, change the grease. Remove plug (5) in
order to allow the water to drain. When you
Illustration 467
g00845075 reinstall plug (5), inspect O-ring seal (6). Replace
the O-ring seal if damage is evident.
The access cover is located in the battery compartment.

g00101644
g00837649 Illustration 470
Illustration 468

6. Raise the boom and turn the upper structure by 90

1. Remove bolts (1) and washers (2). Remove cover
degrees. Lower the bucket to the ground.
(3) and gasket (4).
7. Repeat Step 6 at every 90 degrees in 4 places.
2. Inspect gasket (4). Replace the gasket if damage
Add grease, as needed.
is evident.
SEBU7824-11 287
Maintenance Section
Track Adjustment - Adjust

i03091797

Track Adjustment - Adjust

SMCS Code: 4170-025

Personal injury or death can result from grease

under pressure.

Grease coming out of the relief valve under pres-

sure can penetrate the body causing injury or
death.
g00101752
Illustration 472
Do not watch the relief valve to see if grease is es-
caping. Watch the track or track adjustment cylin-
3. Place a straight edge on top of the track grousers
der to see if the track is being loosened.
between the front carrier roller and the idler. The
straight edge should be long enough to reach from
Loosen the relief valve one turn only.
the front carrier roller to the idler.
If track does not loosen, close the relief valve and
Note: If your machine is equipped with three carrier
contact your Caterpillar dealer.
rollers, place a straight edge on the tracks between
the carrier rollers. The straight edge should be long
NOTICE enough to reach from one carrier roller to another
Keeping the track properly adjusted will increase the carrier roller.
service life of the track and drive components.
4. Measure the maximum amount of sag in the track.
The sag is measured from the highest point of the
Note: The track tension must be adjusted according track grouser to the bottom of the straight edge. A
to the current operating conditions. Keep the track as track that is properly adjusted will have a sag of
slack as possible if the soil is heavy. 40.0 to 55.0 mm (1.57 to 2.17 inch).

Measuring Track Tension 5. If the track is too tight, or if the track is too
loose, adjust the track tension according to the
1. Operate the machine in the direction of the idlers. appropriate procedure below.

Adjusting Track Tension

g01103855
Illustration 471

2. Stop with one track pin directly over the front Illustration 473
g00270405
carrier roller. Park the machine and turn off the Typical example
engine.
The track adjuster is located on the track frame.
288 SEBU7824-11
Maintenance Section
Track Adjustment - Inspect

Tightening the Track 4. Check the amount of sag. Adjust the track, as
needed.

i00370385

Track Adjustment - Inspect

SMCS Code: 4170-040

g01091134
Illustration 474
(1) Grease fitting
(2) Relief valve

Wipe the fitting before you add grease.

1. Add grease through grease fitting (1) until the

correct track tension is reached. Illustration 476
g00270359

2. Operate the machine back and forth in order to Check the track adjustment. Check the track for wear
equalize the pressure. and for excessive dirt buildup.

3. Check the amount of sag. Adjust the track, as If the track appears to be too tight or too loose,
needed. see Operation and Maintenance Manual, “Track
Adjustment - Adjust”.
Loosening the Track
i02189519

Travel Alarm - Test

(If Equipped)
SMCS Code: 7429-081

You must move the machine in order to test the travel

alarm.

1. Start the engine. Move the hydraulic lockout

control to the UNLOCKED position.

2. Raise the work tool in order to avoid any obstacles.

Illustration 475
g01091134 Make sure that there is adequate overhead
(1) Grease fitting clearance.
(2) Relief valve

1. Loosen relief valve (2) carefully until the track

begins to loosen. One turn should be the
maximum.

2. Tighten relief valve (2) to 34 ± 5 N·m (25 ± 4 lb ft)

when the desired track tension is reached.

3. Operate the machine back and forth in order to

equalize the pressure.
SEBU7824-11 289
Maintenance Section
Undercarriage - Check

i03934011

Undercarriage - Check
SMCS Code: 4150-535

g00560313
Illustration 477

3. Use the travel levers or the travel pedals to move

the machine forward. The travel alarm should
sound. g02154815
Illustration 479
4. Release the travel levers and the travel pedals in
order to stop the machine. 1. Check the carrier rollers, the track rollers, and the
idler wheels for possible leakage.
5. Use the travel levers or the travel pedals to move
the machine backward. The travel alarm should 2. Check the surface of the track, the carrier rollers,
sound. the track rollers, the idler wheels, the track shoes,
and the drive sprockets. Look for signs of wear
and loose mounting bolts.

3. Listen for any abnormal noises while you are

moving slowly in an open area.

4. If abnormal wear exists or abnormal noises or

leaks are found, consult your Caterpillar dealer.

i02270212

Window Washer Reservoir -

Fill
g01112898
Illustration 478 SMCS Code: 7306-544-KE

6. Push the alarm cancel switch. The travel alarm NOTICE

should shut off. When operating in freezing temperatures, use
Caterpillar or any commercially available nonfreezing
7. Stop the machine. Lower the work tool. Move the window washer solvent.
hydraulic lockout control to the LOCKED position.
Stop the engine.
1. Open the small storage compartment that
is located on the floor in front of the engine
compartment.
290 SEBU7824-11
Maintenance Section
Window Wiper - Inspect/Replace

g01105820 g00566124
Illustration 480 Illustration 481
Typical example
2. Remove the filler cap.

3. Fill the window washer reservoir with washer fluid Cleaning Methods
through the filler opening.
Aircraft Window Cleaner
4. Install the filler cap.
Apply the cleaner with a soft cloth. Rub the window
5. Close the access door. with moderate pressure until all the dirt is removed.
Allow the cleaner to dry. Wipe off the cleaner with a
clean soft cloth.
i01258249

Window Wiper - Soap and Water

Inspect/Replace Use a clean sponge or a soft cloth. Wash the windows
with a mild soap or with a mild detergent. Also
SMCS Code: 7305-040; 7305-510 use plenty of lukewarm water. Rinse the windows
thoroughly. Dry the windows with a moist chamois or
Inspect the condition of the wiper blades. Replace with a moist cellulose sponge.
the wiper blades if the wiper blades are worn or
damaged or if streaking occurs.
Stubborn Dirt and Grease
i03912371 Wash the windows with a good grade of naphtha, of
isopropyl alcohol, or of Butyl Cellosolve. Then, wash
Windows - Clean the windows with soap and with water.

SMCS Code: 7310-070; 7340-070

Polycarbonate Windows (If
Clean the outside of the windows from the ground, equipped)
unless handholds are available.
Wash polycarbonate windows with a mild soap
or detergent. Never use a cleaning solvent on
polycarbonate windows.

Wash polycarbonate windows with warm water and a

soft sponge, or damp cloth. Never use a dry cloth or
paper towels on polycarbonate windows.

Rinse the windows with a sufficient amount of clean

water.