320B, 322B and 325B Excavators-Maintenance Intervals

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320B, 322B and 325B EXCAVATORS Maintenance Intervals

Excerpted from Operation & Maintenance Manual (SEBU6988-03-01)

© 2007 Caterpillar

®

265 Maintenance Section Maintenance Interval Schedule

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Maintenance Interval Schedule SMCS Code: 7000 Note: All safety information, warnings, and instructions must be read and understood before you perform any operation or any maintenance procedure. Before each consecutive interval is performed, all of the maintenance requirements from the previous interval must also be performed.

When Required Air Conditioner/Cab Heater Filter - Inspect/ Replace ................... .............................. ..................... .................... .................... ............ 267 Battery - Recycle .................... .............................. .................... .................. ........ 267 Battery, Battery Cable or Battery Disconnect Switch Replace ................... .............................. ..................... .................... .................... ............ 269 Boom Base Pins - Lubricate ............................... 269 Bucket Linkage - Inspect/Adjust .......................... 275 Bucket Tips - Inspect/Replace ............................ 276 Cab Air Filter - Clean/Replace ............................ 277 Circuit Breakers - Reset ...................................... 278 Engine Air Filter Primary Element Clean/Replace .................... ............................... ..................... ................... ......... 288 Engine Air Filter Secondary Element - Replace .. 290 Engine Air Filter Service Indicator Indicator - Inspect ........ ........ 291 Ether Starting Aid Cylinder - Replace ................. 297 Fuses - Replace .................... ............................... ..................... ................... ......... 308 Hydraulic Hydraulic System Bio Filter Element Element - Replace .. 310 Oil Filter - Inspect ................................................ 326 Refueling Pump Strainer - Clean ........................ 327 Track Adjustment - Adjust ................................... 334 Windshield Washer Reservoir - Fill ..................... 341 Windshield Wipers - Inspect/Replace ................. 342

Every 10 Service Hours or Daily for First 100 Hours Boom and Stick Linkage - Lubricate ................... 270 Boom, Fore Boom and Stick Linkage Lubricate ..................... ............................... .................... .................... .................. ........ 271 Boom, Stick and Bucket Linkage - Lubricate ...... 273

Every 10 Service Hours or Daily Cooling System Level - Check ............................ 286 Engine Oil Level - Check .................... .............................. ................ ...... 293 Fuel System Water Separator - Drain ................. 306 Fuel Tank Water and Sediment - Drain ............... 308 Hydraulic System Oil Level - Check .................... 318 Indicators and Gauges - Test .............................. 325 Radiator Core - Clean ......................................... 327 Seat Belt - Inspect ................... .............................. ..................... ................ ...... 328 Swing Out Hydraulic Oil Cooler - Clean .............. 333 Track Adjustment - Inspect .................... .............................. .............. .... 335 Travel Alarm - Test ................... .............................. ..................... ................ ...... 336

Undercarriage - Check ..................... ............................... ................... ......... 337 Walk-Around Walk-Around Inspection ........................... ..................................... ............ 339 Windows - Clean ........................ .................................. ..................... ............... .... 341

Every 10 Service Hours or Daily for Machines Used in Severe Severe Applications Boom and Stick Linkage - Lubricate ................... 270 Boom, Fore Boom and Stick Linkage Lubricate .................... .............................. .................... ..................... ................... ........ 271 Boom, Stick and Bucket Linkage - Lubricate ...... 273

Every 50 Service Hours or Weekly Boom and Stick Linkage - Lubricate ................... 270 Boom, Fore Boom and Stick Linkage Lubricate .................... .............................. .................... ..................... ................... ........ 271 Boom, Stick and Bucket Linkage - Lubricate ...... 273 Expandable Pin - Tighten .................... .............................. ............... ..... 298 Quick Coupler - Lubricate ................................... 326

Every 50 Service Hours or Weekly After Initial 500 Hours Hydraulic System Bio Filter Pressure Gauge Inspect .................... .............................. ..................... ..................... .................... ............ 311

Initial 250 Service Hours Final Drive Oil - Change ..................... ............................... ................ ...... 299 Hydraulic System Oil Filter - Replace ................. 316 Swing Drive Oil - Change .................... .............................. ............... ..... 329

Every 250 Service Hours or Monthly Condenser (Refrigerant) - Clean ........................ 278 Cooling Cooling System System Coolant Coolant Additive Additive (DEAC) (DEAC) - Add .. 283 Cooling System Coolant Sample - Obtain .......... 285 Cooling System Hoses - Inspect ..................... ......................... .... 285 Engine Oil Sample - Obtain ................................ 294 Engine Oil and Filter - Change ........................... 295 Final Drive Oil Level - Check ..................... ............................... .......... 300 Final Drive Oil Sample - Obtain .......................... 300 Fuel System Primary Filter/Water Separator Element - Replace .................... .............................. .................... ..................... ................... ........ 301 Fuel System Priming Pump - Operate ................ 302 Fuel System Secondary Filter Number One Replace ..................... ............................... .................... .................... .................... .......... 303 Hydraulic System Oil Sample - Obtain ............... 325 Swing Bearing - Lubricate ..................... ............................... ............. ... 329 Swing Drive Oil Level - Check .................... ............................. ......... 330 Swing Drive Oil Sample - Obtain ........................ 331 V-Belts - Inspect/Adjust/Replace ........................ 337

Every 250 Service Hours or Monthly Before Initial 500 Hours Hydraulic System Bio Filter Pressure Gauge Inspect .................... .............................. ..................... ..................... .................... ............ 311


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Maintenance Interval Schedule SMCS Code: 7000 Note: All safety information, warnings, and instructions must be read and understood before you perform any operation or any maintenance procedure. Before each consecutive interval is performed, all of the maintenance requirements from the previous interval must also be performed.

When Required Air Conditioner/Cab Heater Filter - Inspect/ Replace ................... .............................. ..................... .................... .................... ............ 267 Battery - Recycle .................... .............................. .................... .................. ........ 267 Battery, Battery Cable or Battery Disconnect Switch Replace ................... .............................. ..................... .................... .................... ............ 269 Boom Base Pins - Lubricate ............................... 269 Bucket Linkage - Inspect/Adjust .......................... 275 Bucket Tips - Inspect/Replace ............................ 276 Cab Air Filter - Clean/Replace ............................ 277 Circuit Breakers - Reset ...................................... 278 Engine Air Filter Primary Element Clean/Replace .................... ............................... ..................... ................... ......... 288 Engine Air Filter Secondary Element - Replace .. 290 Engine Air Filter Service Indicator Indicator - Inspect ........ ........ 291 Ether Starting Aid Cylinder - Replace ................. 297 Fuses - Replace .................... ............................... ..................... ................... ......... 308 Hydraulic Hydraulic System Bio Filter Element Element - Replace .. 310 Oil Filter - Inspect ................................................ 326 Refueling Pump Strainer - Clean ........................ 327 Track Adjustment - Adjust ................................... 334 Windshield Washer Reservoir - Fill ..................... 341 Windshield Wipers - Inspect/Replace ................. 342

Every 10 Service Hours or Daily for First 100 Hours Boom and Stick Linkage - Lubricate ................... 270 Boom, Fore Boom and Stick Linkage Lubricate ..................... ............................... .................... .................... .................. ........ 271 Boom, Stick and Bucket Linkage - Lubricate ...... 273

Every 10 Service Hours or Daily Cooling System Level - Check ............................ 286 Engine Oil Level - Check .................... .............................. ................ ...... 293 Fuel System Water Separator - Drain ................. 306 Fuel Tank Water and Sediment - Drain ............... 308 Hydraulic System Oil Level - Check .................... 318 Indicators and Gauges - Test .............................. 325 Radiator Core - Clean ......................................... 327 Seat Belt - Inspect ................... .............................. ..................... ................ ...... 328 Swing Out Hydraulic Oil Cooler - Clean .............. 333 Track Adjustment - Inspect .................... .............................. .............. .... 335 Travel Alarm - Test ................... .............................. ..................... ................ ...... 336

Undercarriage - Check ..................... ............................... ................... ......... 337 Walk-Around Walk-Around Inspection ........................... ..................................... ............ 339 Windows - Clean ........................ .................................. ..................... ............... .... 341

Every 10 Service Hours or Daily for Machines Used in Severe Severe Applications Boom and Stick Linkage - Lubricate ................... 270 Boom, Fore Boom and Stick Linkage Lubricate .................... .............................. .................... ..................... ................... ........ 271 Boom, Stick and Bucket Linkage - Lubricate ...... 273

Every 50 Service Hours or Weekly Boom and Stick Linkage - Lubricate ................... 270 Boom, Fore Boom and Stick Linkage Lubricate .................... .............................. .................... ..................... ................... ........ 271 Boom, Stick and Bucket Linkage - Lubricate ...... 273 Expandable Pin - Tighten .................... .............................. ............... ..... 298 Quick Coupler - Lubricate ................................... 326

Every 50 Service Hours or Weekly After Initial 500 Hours Hydraulic System Bio Filter Pressure Gauge Inspect .................... .............................. ..................... ..................... .................... ............ 311

Initial 250 Service Hours Final Drive Oil - Change ..................... ............................... ................ ...... 299 Hydraulic System Oil Filter - Replace ................. 316 Swing Drive Oil - Change .................... .............................. ............... ..... 329

Every 250 Service Hours or Monthly Condenser (Refrigerant) - Clean ........................ 278 Cooling Cooling System System Coolant Coolant Additive Additive (DEAC) (DEAC) - Add .. 283 Cooling System Coolant Sample - Obtain .......... 285 Cooling System Hoses - Inspect ..................... ......................... .... 285 Engine Oil Sample - Obtain ................................ 294 Engine Oil and Filter - Change ........................... 295 Final Drive Oil Level - Check ..................... ............................... .......... 300 Final Drive Oil Sample - Obtain .......................... 300 Fuel System Primary Filter/Water Separator Element - Replace .................... .............................. .................... ..................... ................... ........ 301 Fuel System Priming Pump - Operate ................ 302 Fuel System Secondary Filter Number One Replace ..................... ............................... .................... .................... .................... .......... 303 Hydraulic System Oil Sample - Obtain ............... 325 Swing Bearing - Lubricate ..................... ............................... ............. ... 329 Swing Drive Oil Level - Check .................... ............................. ......... 330 Swing Drive Oil Sample - Obtain ........................ 331 V-Belts - Inspect/Adjust/Replace ........................ 337

Every 250 Service Hours or Monthly Before Initial 500 Hours Hydraulic System Bio Filter Pressure Gauge Inspect .................... .............................. ..................... ..................... .................... ............ 311


Every 500 Service Hours or 3 Months Engine Crankcase Breather - Clean ................... 291 Fuel System Secondary Filter Number Two Replace ................... .............................. ..................... .................... .................... ............ 305 Fuel Tank Tank Cap and Strainer - Clean ................... ................... 307 Hydraulic System Oil Filter - Replace ................. 316

Every 1000 Service Hours or 6 Months Battery Electrolyte Level - Check ........................ 268 Hydraulic Hydraulic System System Oil Return Filter - Replace ..... ..... 320 Swing Drive Oil - Change .................... ............................... ............... .... 329

Every 2000 Service Hours or 1 Year Engine Governor Oil Supply Screen Clean/Inspect/Replace ........................... ...................................... ........... 292 Engine Valve Lash and Fuel Injector Timing Check .................... .............................. .................... .................... .................... .............. .... 297 Final Drive Oil - Change ................... .............................. .................. ....... 299 Hydraulic System Oil - Change ........................... 312 Swing Gear - Lubricate ....................................... 331

Every 3000 Service Hours or 2 Years Cooling System Coolant (DEAC) - Change ........ 279

Every 3000 Service Hours or 3 Years Cooling System System Coolant Extender Extender (ELC) - Add .. 284

Every 3 Years Seat Belt - Replace ............................................. 328

Every 6000 Service Hours or 6 Years Cooling System Coolant (ELC) - Change ........... 281

267 Maintenance Section Air Conditioner/Cab Heater Filter - Inspect/Replace

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Air Conditioner/Cab Heater Filter - Inspect/Replace SMCS Code: 7309-040; 7309-510

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Battery - Recycle SMCS Code: 1401-561 Always recycle a battery. Never discard a battery.

NOTICE An air filter element plugged with dust will result in decreased performance and service life to the air conditioner or cab heater (if equipped).

Always return used batteries to one of the following locations:

To prevent decreased performance, clean the air filter element, as required.

• An authorized battery collection facility

• A battery supplier

• Recycling facility

Illustration 159

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The air conditioner filter is located behind the operator’s seat.

1. Slide the operator seat forward. 2. Loosen the bolts and remove the cover. 3. Slide the filter element outward. 4. Clean the filter element with a maximum of 200 kPa (30 psi) pressure air. 5. 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 that the filter element is dry. 6. Install the filter element and the cover.

268 Maintenance Section Battery Electrolyte Level - Check

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Battery Electrolyte Level Check SMCS Code: 1401-535 Table 243

Maintenance Intervals for Batteries Battery

Interval

Conventional

100 Hours

Low Maintenance

250 Hours

Maintenance Free

Maintenance Free

Tighten the battery retainers on all machines at every 1000 hour interval. Keep the terminals clean and coated with petroleum jelly. Clean the top of the batteries with a clean cloth at every 1000 hour interval or more often, if necessary. Each battery cell should not require more than 30 cc (1 oz) of water weekly. This usage of water is typical with the proper charging rate and with a moderate climate. When you are operating the machine in extreme temperatures, check the water in the battery cells weekly.

Illustration 160

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1. Open the battery access covers that are on the left side of the rear of the machine.

Illustration 161

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2. Clean the battery surface with a clean cloth. Keep the terminals clean and keep the terminals coated with petroleum jelly. Install the post cover after you coat the terminal post with petroleum jelly. 3. Inspect the electrolyte level in each battery cell. (A maintenance free battery does not require inspection.) Maintain the electrolyte level to the bottom of the filler openings. Use distilled water. If distilled water is not available, use clean drinking water. 4. Close the battery access covers.

269 Maintenance Section Battery, Battery Cable or Battery Disconnect Switch - Replace

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Battery, Battery Cable or Battery Disconnect Switch Replace SMCS Code: 1401-510; 1402-510; 1402-510

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Boom Base Pins - Lubricate SMCS Code: 6501-086 When the boom pin is replaced, lubricate the new boom pin.

1. Turn the engine start switch key to the OFF position. Turn all of the switches to the OFF position. 2. Turn the battery disconnect switch to the OFF position. Remove the disconnect switch key. 3. Disconnect the battery cable at the battery disconnect switch. The battery disconnect switch is connected to the machine frame. Note: Do not allow the disconnected battery cable to contact the battery disconnect switch. 4. Disconnect the negative battery cable at the battery that is connected to the battery disconnect switch. If the machine has four 12 volt batteries, disconnect the negative battery cables of two of the batteries.

Illustration 162

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

5. Make any necessary repairs or replace the battery. 6. Reconnect the negative battery cable at the battery that is connected to the battery disconnect switch. 7. Reconnect the battery cable at the battery disconnect switch. 8. Install the disconnect switch key and turn the battery disconnect switch to the ON position. Illustration 163

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(1) Vent plug. (2) Fitting.

2. Vent plug (1) and fitting (2) are on the base of the boom. Remove vent plug (1). Apply lubricant through fitting (2) until lubricant comes out of the plug hole. 3. Install vent plug (1).

270 Maintenance Section Boom and Stick Linkage - Lubricate

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Boom and Stick Linkage Lubricate SMCS Code: 6501-086; 6502-086 S/N: 5BS1-Up S/N: 9WS1-Up S/N: 6LW1-Up

Material Handler Note: For some applications of the machine, the repeated duty cycle of the front linkage may only require small angular movements of the boom or stick. There might not be enough angular motion in order to distribute the grease between the pin and the bearing. The operator should operate the boom, the stick and the implement in order to distribute the grease within the joint assemblies.

Illustration 165

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1. Apply lubricant through the fitting at the base of each boom cylinder.

Note: Caterpillar recommends the use of 5P-0960 Molybdenum Grease for lubricating the boom and stick linkage. Refer to Operation and Maintenance Manual, “Lubricating Grease” for more information on molybdenum grease.

Illustration 166

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

Illustration 164

Wipe all fittings before you apply lubricant.

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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 implement is suspended. Then apply lubricant when the boom is lowered and the implement is rested on the ground with a slight downward pressure.

271 Maintenance Section Boom, Fore Boom and Stick Linkage - Lubricate

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Boom, Fore Boom and Stick Linkage - Lubricate (If Equipped) SMCS Code: 6501-086; 6502-086; 6535-086 S/N: 4DS1-Up

Illustration 167

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Note: Caterpillar recommends the use of 5P-0960 Molybdenum Grease for lubricating the boom, fore boom, stick and bucket linkage. Refer to Operation and Maintenance Manual, “Lubricating Grease” for more information on molybdenum grease.

3. The fittings are located at the end of the stick. Apply lubricant through fittings (6) and (8) in order to lubricate the connection point of the boom and the stick. Apply lubricant through fitting (7) in order to lubricate the rod end of the stick cylinder.

Illustration 168

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Illustration 169

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272 Maintenance Section Boom, Fore Boom and Stick Linkage - Lubricate

4. Apply lubricant through fittings (10), (11), and (12). These fittings are on the bucket.

Illustration 170

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2. The fittings are at the base of the boom. The fittings can be serviced from the platform that is on the 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). Use Steps 2.a through 2.d to ensure proper lubrication of the lower boom bearings and of the boom cylinder rod end bearings.

Illustration 172

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5. The fittings are located at the base of the fore boom. The fitting can be serviced from the ground. To lubricate the connection point between the boom and the fore boom, apply lubricant through fittings (13). To lubricate the cylinder rod end of the fore boom, apply lubricant through fitting (14). To lubricate the stick cylinder head, apply lubricant through fitting (15).

a. Apply grease through the grease fitting while the boom is raised and the implement is suspended. b. Lower the boom and the implement to the ground. c. Apply a slight downward pressure on the implement. d. Apply grease through the grease fitting. Illustration 173

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6. The fittings are located at the connection point between the fore boom and the stick. To lubricate the connection point between the fore boom and the stick, apply lubricant through fittings (16).

Illustration 171

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3. Apply lubricant through fittings (6), (7), (8), and (9). These fittings are on the link.

273 Maintenance Section Boom, Stick and Bucket Linkage - Lubricate

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Boom, Stick and Bucket Linkage - Lubricate SMCS Code: 6501-086; 6502-086; 6513-086 Note: Caterpillar recommends the use of 5P-0960 Molybdenum Grease for lubricating the boom, stick and bucket linkage. Refer to Operation and Maintenance Manual, “Lubricating Grease” for more information on molybdenum grease.

Illustration 174

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7. To lubricate the stick cylinder rod, apply lubricant through fitting (17). To lubricate the bucket cylinder head end, apply lubricant through fitting (18).

Illustration 175

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Illustration 176

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274 Maintenance Section Boom, Stick and Bucket Linkage - Lubricate

4. Apply lubricant through fittings (10), (11), and (12). These fittings are on the bucket.

Illustration 177

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2. The fittings are at the base of the boom. The fittings can be serviced from the platform that is on the 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).

Illustration 179

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5.

Use Steps 2.a through 2.d to ensure proper lubrication of the lower boom bearings and of the boom cylinder rod end bearings.

a. Apply grease through the grease fitting while the boom is raised and all of the implement is suspended. b. Lower the boom and the implement to the ground. c. Apply a slight downward pressure on the implement. d. Apply grease through the grease fitting.

Illustration 178

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3. Apply lubricant through fittings (6), (7), (8), and (9). These fittings are on the link.

Illustration 180

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6. Apply lubricant through fitting (14) on the stick cylinder rod. Apply lubricant through two fittings (13). Fittings (13) are at the connection point of the boom and of the stick. Apply lubricant through fitting (15) on the bucket cylinder head end.

275 Maintenance Section Bucket Linkage - Inspect/Adjust

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Bucket Linkage Inspect/Adjust SMCS Code: 6513-025; 6513-040

When performing this adjustment, put the hydraulic activation control lever in the LOCKED position and stop the engine. 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.

Illustration 182

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Area for linkage adjustment

1. Position the machine on a level surface and lower the bucket to the ground. 2. Slowly operate the swing control lever until stick boss (2) and the bucket boss (11) are in full face contact at no gap (1). This will help to determine the total clearance of the connection point of the stick and of the bucket. 3. Place the hydraulic activation control lever in the LOCKED position and stop the engine. 4. Measure bucket clearance (3), which is the existing total clearance.

Illustration 181

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

The clearance of the bucket linkage on this machine can be adjusted by shimming. If the gap between the bucket and the stick becomes excessive, adjust bucket clearance (3) to 0.5 to 1 mm (.02 to .04 inch). Two shims of different thickness are used at location (9). The thicknesses of the shims are 0.5 mm (0.02 inch ) and 1.0 mm (0.04 inch).

5. Determine the number of shims that need to be removed from shims (4) by using the following calculation: Subtract 0.5 mm (0.02 inch ) or 1.0 mm (0.04 inch) from bucket clearance (3).

6. Remove the appropriate number of shims at location (9) in order to meet the above thickness. Make sure that you use a minimum of three 0.5 mm (.02 inch) shims. To remove the shims, remove bolts (7), washers (8), and plate (6). 7. After the correct number of shims has been removed and pin (5) is aligned with the pin hole, install plate (6), washers (8), and bolts (7). Tighten bolts (7) to a torque of 460 ± 60 N·m (340 ± 44 lb ft). 8. After installation, make sure that bucket clearance (3) is still correct.

276 Maintenance Section Bucket Tips - Inspect/Replace

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Bucket Tips - Inspect/Replace SMCS Code: 6805-040; 6805-510

Personal injury or death can result from bucket falling. Block the bucket before changing bucket tips or side cutters. Illustration 185

Bucket Tips

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2. Clean the adapter and the pin. 3. Fit retainer (1) into retainer washer (2). Install this assembly into the groove that is in the side of adapter (3).

Illustration 183

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(1) This tip is usable. (2) This tip should be replaced. (3) This tip has been overworn.

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

Illustration 186

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4. Install the new bucket tip or the rotated bucket tip onto the adapter. To allow greater penetration or less penetration, the bucket tip may be rotated by 180 degrees. 5. From the other side of the retainer, drive the pin through the bucket tip, through the adapter, and through the retainer. 6. After you drive the pin, make sure that the retainer fits snugly into the pin groove.

Illustration 184

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1. Drive the pin out of the bucket tip from the retainer side of the bucket tip. Remove the bucket tip and the retainer.

277 Maintenance Section Cab Air Filter - Clean/Replace

Side Cutters

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

Illustration 187

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1. Remove the mounting bolts and the side cutters. 2. Clean the mounting surfaces.

Illustration 188

Note: Some side cutters may be rotated for additional wear.

The cab air filter is behind the cab.

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

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1. Loosen two bolts (1) and remove filter cover (2) and air filter (3). 2. Clean the air filter with a maximum of 200 kPa (30 psi) pressure air. 3. After you clean the air filter, inspect the air filter. If the air filter is damaged or badly contaminated, use a new air filter. 4. Install the air filter and the filter cover. Note: Make sure that the arrow on top of the air filter is facing forward.

278 Maintenance Section Circuit Breakers - Reset

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Circuit Breakers - Reset

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Condenser (Refrigerant) Clean (If Equipped)

SMCS Code: 1420-529

SMCS Code: 1805-070 NOTICE If excessively dirty, clean condenser with a brush. To prevent damage or bending of the fins, do not use a stiff brush. Repair the fins if found defective.

Illustration 189

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

Alternator Circuit (1) – This circuit breaker is designed to protect the alternator. If the batteries are installed with reversed polarity, the circuit breaker would prevent the alternator from damaging the rectifier. Main Circuit (2) – This circuit breaker is designed to protect the wires between the batteries and the fuses. If the wires are shorted to the machine’s body, this circuit breaker would minimize the damage to the wires.

Illustration 190

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1. Open the access door that is on the left side of the machine.

Both circuit breakers have a capacity of 60 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.

Illustration 191

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2. Inspect the condenser for debris. Clean the condenser, if necessary. 3. Use clean water to wash off all dust and dirt from the condenser. 4. Close the access door.

279 Maintenance Section Cooling System Coolant (DEAC) - Change

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Cooling System Coolant (DEAC) - Change SMCS Code: 1350-044; 1352-544 NOTICE Do not change the coolant until you read and understand the material found in the Operation and Maintenance Manual, “Cooling System Specifications” section. Failure to do so could result in damage to the cooling systems components. Note: This machine was filled at the factory with Caterpillar Extended Life Coolant. The following information pertains to machines which have been subsequently filled with Caterpillar Diesel Engine Antifreeze/Coolant (DEAC) or a commercial equivalent.

Illustration 193

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

See Operation and Maintenance Manual, “Cooling System Specifications” for all cooling system requirements. If the coolant is dirty or if you observe any foaming in the cooling system, drain the coolant before the recommended interval.

Illustration 194

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Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on containing fluid spillage. 3. Open the drain valve that is under the radiator. Allow the coolant to drain into a suitable container. Illustration 192

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1. Unlatch the engine hood and raise the engine hood.

4. Close the drain valve. 5. Fill the cooling system with a solution which consists of clean water and cooling system cleaner. The concentration of the cooling system cleaner should be 6 to 10 percent. 6. Start the engine. Operate the engine without the cooling system pressure cap until the water temperature regulator opens and the cooling system level stabilizes. 7. Maintain the cooling system level within 13 mm (.5 inches) of the bottom of the filler pipe. 8. Install the cooling system pressure cap.

280 Maintenance Section Cooling System Coolant (DEAC) - Change

9. Operate the engine for 90 minutes. 10. Stop the engine.

Pressurized System: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure. 11. Slowly loosen the cooling system pressure cap in order to relieve system pressure. Remove the pressure cap. 12. Drain the cleaning solution into a suitable container.

Illustration 195

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21. Open the access door on the left side of the machine.

Note: Dispose of drained fluids according to local regulations. 13. Flush the cooling system with water until the draining water is transparent. 14. Close the drain valve. 15. Add the appropriate coolant solution to the cooling system. Refer to the following topics:

• Operation and Maintenance Manual, “Cooling System Specifications”

• Operation and Maintenance Manual, “Refill Capacities”

Note: If you are using Caterpillar antifreeze, do not add the supplemental coolant additive at this time. Also, do not replace the supplemental coolant additive element at this time. 16. Start the engine. Operate the engine without the cooling system pressure cap until the water temperature regulator opens and the coolant level stabilizes. 17. Maintain the coolant level within 13 mm (.5 inches) of the bottom of the filler pipe. 18. Inspect the gasket of the cooling system pressure cap. If the gasket is damaged, replace the pressure cap. 19. Install the cooling system pressure cap. 20. Stop the engine.

Illustration 196

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(A) “FULL” level (B) “LOW” level

22. Check the coolant level of the coolant reservoir. Maintain the coolant level between the “FULL” mark and the “LOW” mark. 23. If additional coolant is necessary, remove the reservoir cap and add the appropriate coolant solution. 24. Install the reservoir cap. 25. Close the engine hood and latch the engine hood. 26. Close the access door.

281 Maintenance Section Cooling System Coolant (ELC) - Change

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Cooling System Coolant (ELC) - Change SMCS Code: 1350-044 NOTICE Do not change the coolant until you read and understand the material found in the Operation and Maintenance Manual, “Cooling System Specifications” section. Failure to do so could result in damage to the cooling systems components. NOTICE Mixing ELC with other products reduces the effectiveness of the coolant and shortens coolant life. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specifications for pre-mixed or concentrate coolants. Use only Caterpillar Extender with Caterpillar ELC. Failure to follow these recommendations could result in the damage to cooling systems components.

Illustration 198

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

If ELC cooling system contamination occurs see the topic ELC Cooling System Contamination of this operation and maintenance manual. If the coolant in the machine is changed to Extended Life Coolant from another type of coolant, see Operation and Maintenance Manual, “Extended Life Coolant Cooling System Maintenance”. Illustration 199

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Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on containing fluid spillage. 3. Open the drain valve that is under the radiator. Allow the coolant to drain into a suitable container. 4. Flush the cooling system with clean water until the draining water is transparent. 5. Close the drain valve. Illustration 197

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6. Add the Extended Life Coolant. Refer to the following topics:



282 Maintenance Section Cooling System Coolant (ELC) - Change

7. Start the engine. Operate the engine without the cooling system pressure cap until the water temperature regulator opens and the coolant level stabilizes. 8. Maintain the coolant level within 13 mm (.5 inches) of the bottom of the filler pipe. 9. Inspect the gasket of the cooling system pressure cap. If the gasket is damaged, replace the pressure cap. 10. Install the cooling system pressure cap. 11. Stop the engine.

Illustration 200

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Illustration 201

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(A) “FULL” level (B) “LOW” level

13. Check the coolant level of the coolant reservoir. Maintain the coolant level between the “FULL” mark and the “LOW” mark. 14. If additional coolant is necessary, remove the reservoir cap and add the appropriate coolant solution.

16. Close the engine hood and latch the engine hood. 17. Close the access door.

283 Maintenance Section Cooling System Coolant Additive (DEAC) - Add

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Cooling System Coolant Additive (DEAC) - Add SMCS Code: 1352; 1353; 1395 Note: This machine was filled at the factory with Caterpillar Extended Life Coolant. The following information pertains to machines which have been subsequently filled with Caterpillar Diesel Engine Antifreeze/Coolant (DEAC) or a commercial equivalent. See the Cooling System Specifications in the Operation and Maintenance Manual for all cooling system requirements. Check the concentration of the coolant. Use 8T-5296 Coolant Conditioner Test Kit to check the concentration. If necessary, add Caterpillar Supplemental Coolant Additive (SCA).

NOTICE Excessive additive (greater than the recommended 6% initial fill) together with concentrations of antifreeze greater than 60% cause deposits to form and can result in radiator tube blockage and overheating.

Liquid Supplemental Coolant Additive

Illustration 203

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2. Slowly loosen the cooling system pressure cap in order to relieve system pressure. Remove the pressure cap. Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on containing fluid spillage. 3. It may be necessary to drain some coolant from the radiator so that Caterpillar Supplemental Coolant Additive can be added to the cooling system. Note: Always discard drained fluids according to local regulations. 4. Add the Supplemental Coolant Additive to the cooling system. Refer to the following topics for the proper amount of Caterpillar Supplemental Coolant Additive:

• Operation and Maintenance Manual,

“Supplemental Coolant Additive (SCA)”


5. Inspect the gasket of the cooling system pressure cap. If the gasket is damaged, replace the pressure cap. 6. Install the cooling system pressure cap. Illustration 202

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1. Unlatch the engine hood. Raise the engine hood.

7. Close the engine hood. Latch the engine hood.

284 Maintenance Section Cooling System Coolant Extender (ELC) - Add

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Cooling System Coolant Extender (ELC) - Add SMCS Code: 1352; 1353; 1395 When a Caterpillar Extended Life Coolant (ELC) is used, an Extender must be added to the cooling system. See the Operation and Maintenance Manual, “Cooling Recommendations” for all cooling system requirements. Use a 8T-5296 Coolant Conditioner Test Kit to check the concentration of the coolant.

NOTICE Mixing Extended Life Coolant (ELC) with other products reduces the effectiveness of the coolant and shortens coolant life. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specification for premixed or concentrate coolants. Use only Caterpillar Extender with Caterpillar ELC. Failure to follow these recommendations could result in the damage to cooling systems components. If ELC cooling system contamination occurs refer to Operation and Maintenance Manual, “ELC Cooling System Contamination”. This machine was factory filled with Extended Life Coolant.

Illustration 205

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2. Loosen the cooling system pressure cap slowly in order to relieve system pressure. Remove the pressure cap. Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on containing fluid spillage. 3. It may be necessary to drain some coolant from the radiator so that Caterpillar Extender can be 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:

• Operation and Maintenance Manual, “Extended Life Coolant (ELC)”


5. Inspect the gasket of the pressure cap. Replace the pressure cap if the cap gasket is damaged. Install the pressure cap. 6. Close the engine hood and latch the engine hood. Illustration 204

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285 Maintenance Section Cooling System Coolant Sample - Obtain

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Cooling System Coolant Sample - Obtain

Cooling System Hoses Inspect

SMCS Code: 1350-554-SM

SMCS Code: 1380-040


Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure. 2. Slowly loosen the cooling system pressure cap in order to relieve system pressure. Remove the pressure cap. Illustration 206

3. Obtain a sample of the coolant through the filler pipe of the radiator.

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Note: Refer to Operation and Maintenance Manual, “S·O·S Oil Analysis” for information that pertains to obtaining a sample of the coolant.

Illustration 207

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2. Inspect all hoses for leaks due to cracking, for softness next to the clamps, and for loose clamps. 3. Replace hoses that are cracked or soft and tighten any loose clamps. Use Steps 3.a through 3.f to replace the hoses.

286 Maintenance Section Cooling System Level - Check

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Cooling System Level - Check SMCS Code: 1350-535

Illustration 208

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a. Slowly loosen the cooling system pressure cap in order to relieve system pressure. Remove the pressure cap. Illustration 209

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

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b. Drain the coolant from the cooling system to a level that is below the hose that is being replaced. Note: Dispose of the drained fluids according to local regulations. c. Loosen the hose clamps and disconnect the damaged hose. d. Replace the damaged hose with a new hose. e. Replace the hose clamps and tighten the hose clamps. f. Add the appropriate coolant solution to the cooling system. Refer to the Operation and Maintenance Manual, “Cooling System Level - Check”. 4. Close the engine hood and latch the engine hood.

Illustration 210

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(A) “FULL” Level (B) “LOW” Level

2. Check the coolant level of the coolant reservoir. Maintain the coolant level between the “FULL” mark and the “LOW” mark. If the reservoir is empty, use steps 2.a through 2.i.

287 Maintenance Section Cooling System Level - Check

Illustration 211

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a. Unlatch the engine hood and raise the engine hood.

Illustration 213

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f. Inspect the gasket of the cooling system 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 engine hood and latch the engine hood. Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on containing fluid spillage.

Illustration 212

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b. Slowly loosen the cooling system pressure cap in order to relieve system pressure. Remove the pressure cap. Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on containing fluid spillage. c. Add the appropriate coolant solution to the cooling system. Refer to the following topics:



d. Start the engine. Operate the engine without the cooling system pressure cap until the water temperature regulator opens and the coolant level stabilizes. e. Maintain the coolant level within 13 mm (0.5 inch) of the bottom of the radiator filler pipe.

3. If additional coolant is necessary, remove the reservoir cap and add the appropriate coolant solution. 4. Install the reservoir cap. 5. Close the access door.

288 Maintenance Section Engine Air Filter Primary Element - Clean/Replace

i00174147

Engine Air Filter Primary Element - Clean/Replace

3. Loosen the four cover latches and remove the air cleaner cover.

SMCS Code: 1054-070; 1054-510

Illustration 217

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4. Remove the primary filter element from the air cleaner housing. Illustration 214

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5. Clean the air cleaner cover and the inside of the air cleaner housing. 6. Inspect the O-ring seal on the air cleaner cover. Replace the O-ring seal if the O-ring seal is worn or damaged. NOTICE Do not clean the filter elements by bumping or tapping them. Do not use filter elements with damaged pleats, gaskets or seals. Engine damage can result. Make sure the cleaned filter elements are completely dry before installing into the filter housing. Water remaining in the elements can cause false indications of contamination in Scheduled Oil Sampling test results.

Illustration 215

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2. Open the front access door on the left side of the machine.

7. Clean the primary filter. Inspect the primary filter. Primary filter elements can be cleaned with pressure air, pressure water or a detergent washing. When pressure water is used the maximum pressure should not exceed 280 kPa (40 psi). Refer to Operation and Maintenance, “General Hazard Information” before you use pressure air in order to clean the primary filter element.

Illustration 216

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289 Maintenance Section Engine Air Filter Primary Element - Clean/Replace

• Restricted Air Filter indicator on the monitor panel still comes on.

• Exhaust smoke is still black after the installation of a primary filter.

Note: The primary filter can be cleaned up to six times. Replace the primary filter if the primary filter has been in service for one year. 14. Close the access doors.

Illustration 218

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8. Direct air or water along the pleats inside the primary filter element and outside the primary filter element. The primary filter element can be washed in warm water and nonsudsing household detergent. Rinse inside the pleats and outside the pleats. Allow the primary filter element to air dry fully.

9. Inspect the primary filter element after cleaning. Do not use a primary filter element with damaged pleats, damaged gaskets or damaged seals. 10. Encase the clean primary filter element and store the clean primary filter element in a clean, dry place. 11. Install the clean primary filter. 12. Install the air cleaner cover and close the latches securely.

Illustration 219

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Note: Install the air cleaner cover properly. The arrows must point upward. 13. Change the filter if any of the following conditions occurs:

290 Maintenance Section Engine Air Filter Secondary Element - Replace

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Engine Air Filter Secondary Element - Replace SMCS Code: 1054-510 NOTICE Always replace the secondary filter element. Never attempt to reuse the secondary filter element by cleaning the element. When the primary filter element is replaced, the secondary filter element should be replaced. The secondary filter element should also be replaced if the restricted Air Filter indicator comes on after the installation of a clean primary filter element or if the exhaust smoke is still black. Note: See Operation and Maintenance Manual, “Engine Air Filter Primary Element - Clean/Replace” for information that pertains to the removal of the air cleaner cover and the removal of the primary filter element. 1. Remove the air cleaner cover from the air cleaner housing. 2. Remove the primary filter element from the air cleaner housing.

Illustration 220

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3. Remove the secondary filter element. 4. Cover the air inlet opening. 5. Clean the inside of the air cleaner housing. 6. Remove the covering from the air inlet opening. 7. Install the new secondary filter element. 8. Install the primary filter element.

9. Install the air cleaner cover and close the latches securely. 10. Close the access door.

291 Maintenance Section Engine Air Filter Service Indicator - Inspect

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Engine Air Filter Service Indicator - Inspect

Engine Crankcase Breather Clean

SMCS Code: 7452-040-DJ

SMCS Code: 1317-070-DJ

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

Illustration 222

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1. Unlatch the engine hood and raise the engine hood. Illustration 221

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Check the air filter indicator while the engine is running under a full load. Service the air cleaner if the restricted air filter indicator on the monitor panel comes on. Stop the engine before you service the air cleaner.

Illustration 223

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2. Loosen hose clamp (1) and disconnect outlet hose (2) from breather (3). 3. Loosen bolt (4). Remove breather (3) and seal. Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on containing fluid spillage. 4. Wash breather (3) in a clean, nonflammable solvent. 5. Inspect the seal. If the seal is damaged, install a new seal. 6. Install the O-ring seal and clean breather (3). Tighten bolt (4) to 14 ± 3 N·m (10 ± 2 lb ft). 7. Slide hose on breather (3). Tighten hose clamp

292 Maintenance Section Engine Governor Oil Supply Screen - Clean/Inspect/Replace

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

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Engine Governor Oil Supply Screen - Clean/Inspect/Replace SMCS Code: 1264-040; 1264-070; 1264-510

Illustration 224

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Illustration 225

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Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on containing fluid spillage. 2. Remove oil supply tube (1) from the cylinder head. Remove fitting (2) and seal (3) from the governor housing. 3. Use a 6 mm hexagon wrench in order to remove oil screen (4). 4. Wash the oil screen in a clean, nonflammable solvent in order to remove any debris. Inspect the oil screen and the seals for damage. If necessary, replace the oil screen. 5. Install the oil screen into the governor housing. The oil screen should be far enough into the

293 Maintenance Section Engine Oil Level - Check

6. Install the seal, the fitting, and the oil supply tube. 7. Close the engine hood and latch the engine hood.

i00093751

Engine Oil Level - Check SMCS Code: 1000-535 NOTICE Do not overfill the crankcase. Engine damage can result. Note: This machine is equipped with a function for checking fluid levels. However, if the machine is on an incline or the engine has been stopped only for a short time, the 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 15 minutes. Check the oil level while the engine is stopped. Do not check the oil level while the engine is running.

Illustration 226

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Illustration 227

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2. Remove dipstick (2). Wipe the oil off the dipstick and reinsert the dipstick.

294 Maintenance Section Engine Oil Sample - Obtain

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Engine Oil Sample - Obtain SMCS Code: 1000-008; 7542-008

Illustration 228

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3. Check the dipstick. The oil level should be between the “FULL” mark and the “ADD” mark. NOTICE Do not fill above the “FULL” mark on the dipstick. If the oil level is above the “FULL” Mark, the crankshaft might dip into the oil during engine operation. This will lead to excessively high oil temperatures. High oil temperatures can reduce the lubricating characteristics of oil.

Illustration 229

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

Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on containing fluid spillage. 4. Remove oil filler plug (1) in order to add oil, if necessary. See Operation and Maintenance Manual, “Refill Capacities”. Note: If the oil is deteriorated or badly contaminated, change the oil regardless of the maintenance interval.

Illustration 230

5. Clean oil filler plug (1). Install oil filler plug (1).

The sampling valve for the engine oil is located on the top of the engine oil filter.

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

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Refer to Operation and Maintenance Manual, “S·O·S Oil Analysis” for more information on obtaining a sample of the engine oil.

295 Maintenance Section Engine Oil and Filter - Change

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Engine Oil and Filter - Change

Note: Dispose of drained fluids according to local regulations. 3. Close the drain valve.

SMCS Code: 1318-510 Note: If the sulfur content in the fuel is greater than 1.5 percent by weight, use an oil that has a TBN of 30 and reduce the oil change interval by one-half.

4. Close the crankcase access cover.

Park the machine on a level surface. Stop the engine.

Note: Drain the crankcase while the oil is warm. This allows waste particles that are suspended in the oil to drain. As the oil cools, the waste particles will settle to the bottom of the crankcase. The particles will not be removed by draining the oil and the particles will recirculate in the engine lubrication system with the new oil. Illustration 233

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5. Open the access door at the right side of the machine.

Illustration 231

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1. Open the crankcase access cover. Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on containing fluid spillage.

Illustration 234

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6. Remove the oil filter with a strap type wrench. See Operation and Maintenance Manual, “Oil Filter - Inspect”. Dispose of the used filter according to local regulations. 7. Clean the filter housing base. Make sure that all of the old filter gasket is removed.

Illustration 232

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2. Open the crankcase drain valve. Allow the oil to drain into a suitable container.

296 Maintenance Section Engine Oil and Filter - Change

Illustration 235

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8. Apply a thin coat of engine oil to the gasket of the new filter. 9. Install the new filter by hand. When the gasket contacts the filter base, turn the filter by 270 degrees more. This will tighten the filter sufficiently. Every new oil filter has rotation index marks that are spaced at 90 degree increments. Use the rotation index marks as a guide for tightening the oil filter.

10. Close the access door.

Illustration 237

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12. Remove oil filler plug (1). Fill the crankcase with new oil. See Operation and Maintenance Manual, “Refill Capacities”. Clean the oil filler plug and install the oil filler plug. NOTICE Do not under fill or overfill engine crankcase with oil. Either condition can cause engine damage. 13. Start the engine and allow the oil to warm. Check the engine for leaks. 14. Run the engine and check dipstick (2) after the engine has been running for fifteen minutes. Maintain the oil between the marks on the dipstick. If necessary, add oil. 15. Close the engine hood and latch the engine hood.

Illustration 236

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297 Maintenance Section Engine Valve Lash and Fuel Injector Timing - Check

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Engine Valve Lash and Fuel Injector Timing - Check SMCS Code: 1102; 1105-025; 1105; 1290-531-FT; 1290

i00719603

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

Refer to the Service Manual for the complete procedure for checking the engine valve lash. This procedure lists the steps for the engine valve lash adjustment and the steps in order to check the engine valve lash.

Note: Make sure that a qualified mechanic works on the injector fuel timing. Special tools and training are required. Refer to the Service Manual for the complete procedure for checking the injector fuel timing or for adjusting the injector fuel timing.

Note: The correct fuel timing specification is given on the Engine Information Plate. Fuel timing specifications may differ for distinct engine applications and/or power ratings.

Illustration 238

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The ether cylinder is located in the radiator compartment.

1. Open the access door at the back left side of the machine.

Illustration 239

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2. Loosen the cylinder retaining clamp. 3. Unscrew the empty ether starting aid cylinder and remove the empty ether starting aid cylinder.

298 Maintenance Section Expandable Pin - Tighten

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Expandable Pin - Tighten (If Equipped) SMCS Code: 6501-527-PN; 6535-527-PN S/N: 4DS1-Up

Illustration 240

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4. Remove the used gasket. 5. Install a new gasket. Note: A new gasket is provided with each new ether starting aid cylinder. 6. Install the new ether starting aid cylinder. 7. Tighten the ether starting aid cylinder hand tight. 8. Tighten the cylinder retaining clamp securely. 9. Close the access door.

Illustration 241

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(1) Expandable pins

Expandable pins (1) are located at the junction between the boom foot and the boom nose. Check the torque on expandable pins (1). Refer to Operation and Maintenance Manual, “Torque for Expandable Pins” for the proper torque specification.

Note: If the pins must be replaced, grease the pin bores, the pins, and the sleeves with Caterpillar TO-2 oil or an equivalent before installing the pins.

299 Maintenance Section Final Drive Oil - Change

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Final Drive Oil - Change SMCS Code: 4050-044-FLV

Illustration 242

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(1) Drain plug. (2) Level plug.

1. Position one final drive so that oil drain plug (1) is at the bottom. Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on containing fluid spillage. 2. Remove drain plug (1) and level plug (2). Allow the oil to drain into a suitable container. Note: Dispose of drained fluids according to local regulations. 3. Clean the plugs and inspect the O-ring seals. If wear or damage is evident, replace the drain plug, the level plug, and/or the O-ring seals. 4. Install drain plug (1). 5. Fill the final drive to the bottom of the opening on level plug (2). See Operation and Maintenance Manual, “Lubricant Viscosities” and Operation and Maintenance Manual, “Refill Capacities”. 6. Install level plug (2). 7. Perform Step 1 to Step 6 on the other final drive. Use a different container for the oil so that the oil samples from the final drives will be separate. 8. Completely remove the oil that has spilled onto surfaces. 9. Start the engine and allow the final drives to run through several cycles. 10. Stop the engine. Check the oil level.

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

300 Maintenance Section Final Drive Oil Level - Check

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Final Drive Oil Level - Check

Final Drive Oil Sample - Obtain

SMCS Code: 4050-535-FLV

SMCS Code: 4050-008

Illustration 243

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(1) Drain plug. (2) Level plug.

1. Position one final drive so that oil drain plug (1) is at the bottom. Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on containing fluid spillage. 2. Remove oil level plug (2). 3. Check the oil level. The oil should be near the bottom of the level plug opening. 4. Add oil through the level plug opening, if necessary. Note: Overfilling the final drive will cause the seals on the travel motor to allow hydraulic oil or water to enter the final drive. This may contaminate the final drive. 5. Clean oil level plug (2). Inspect the O-ring seal. Replace the O-ring seal if the O-ring seal is worn or damaged. 6. Install oil level plug (2). 7. Repeat Steps 1 through 6 for the other final drive.

Illustration 244

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

1. Position the final drive so that oil drain plug (1) is at the bottom. 2. Remove oil level plug (2). 3. Obtain a sample of the final drive oil through the hole for the oil level plug. 4. Install oil level plug (2). Refer to Operation and Maintenance Manual, “S·O·S Oil Analysis” for more information on obtaining a sample of the final drive oil.

301 Maintenance Section Fuel System Primary Filter/Water Separator Element - Replace

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Fuel System Primary Filter/Water Separator Element - Replace SMCS Code: 1260-510; 1263-510

Personal injury or death can result from a fire. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.

Illustration 246

Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system.


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Turn the disconnect switch OFF or disconnect the battery when changing fuel filters. NOTICE Do not fill fuel filters with fuel before installing them. Contaminated fuel will cause accelerated wear to fuel system parts.

Illustration 247

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(1) Collar (2) Primary filter/water separator (3) Collar (4) Drain valve (5) Bowl

3. Turn drain valve (4) counterclockwise in order to open. Illustration 245

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The fuel shutoff valve is located under the fuel tank.

4. Drain the water and the sediment into a suitable container.

1. Turn the fuel supply valve clockwise in order to shut off the fuel supply.

Note: Dispose of drained fluids and used filters according to local regulations. 5. Close drain valve (4). 6. Hold the bottom of primary filter/water separator (2) while you loosen collar (3). 7. Remove bowl (5). 8. Loosen collar (1). 9. Remove primary filter/water separator (2).

302 Maintenance Section Fuel System Priming Pump - Operate

11. Clean the inside surfaces of the filter head and of bowl (5). Note: Dispose of drained fluids and used filters according to local regulations. Note: The primary filter/water separator is a cartridge type filter. The filter cannot be reused.

i00059065

Fuel System Priming Pump Operate SMCS Code: 1258

12. Inspect the O-ring on bowl (5). Also inspect the seal on the filter head. Replace these seals if the seals are worn or damaged. 13. Install a new primary filter/water separator. Tighten collar (1) in order to secure the primary filter/water separator. 14. Install bowl (5). Tighten collar (3). Note: Do not start the engine until all service to the fuel system is complete. For instructions about priming the fuel system, refer to Operation and Maintenance Manual, “Fuel System Priming Pump - Operate”.

Illustration 248

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1. Turn the fuel drain valve counterclockwise to the ON position.

15. Close the access door. 16. Turn the fuel shutoff valve counterclockwise in order to open the fuel supply.

Illustration 249

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2. Unlock the priming pump plunger and operate the priming pump plunger until fuel flows out of the drain hose. 3. Turn the fuel drain valve clockwise to the OFF position. 4. Operate the priming pump plunger for another ten strokes. 5. Push in the priming pump plunger and tighten the priming pump plunger by hand. 6. Crank the engine. If the engine does not start or the engine misfires, additional priming is required. Also if the engine emits smoke, additional priming is required.

303 Maintenance Section Fuel System Secondary Filter Number One - Replace

7. If the engine starts but the engine runs rough, continue to run the engine at low idle. Run the engine at low idle until the engine runs properly. 8. Check the fuel system for leaks. Stop the engine.

i00728372

Fuel System Secondary Filter Number One - Replace (Lower Filter) SMCS Code: 1261-510-SE

Personal injury or death can result from a fire. Fuel leaked or spilled onto hot surfaces or electrical 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 fuel filters with fuel before installing them. Contaminated fuel will cause accelerated wear to fuel system parts.

Illustration 250

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304 Maintenance Section Fuel System Secondary Filter Number One - Replace

Note: Dispose of used filters according to local regulations. 7. Clean the mounting base of the fuel filter. Make sure that all of the old seal is removed from the mounting base.

Illustration 251

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(1) Secondary filter (2) Secondary filter (3) Drain valve (4) Drain valve

Note: Drain upper secondary filter (2) before you remove lower secondary filter (1). Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on containing fluid spillage. 2. Open drain valve (4) and immediately open drain valve (3). Allow the fuel to drain into a suitable container. Note: Make sure that the drain valves are opened in the proper order. If you open the wrong drain valve first, an air lock in the fuel system may occur. This will not allow fuel to drain from the upper filter. 3. Slowly loosen upper secondary filter (2) for 1/4 turn. Allow any remaining fuel in the valves to drain into a suitable container. When the fuel stops draining, loosen upper secondary filter (2) for an additional 1/4 turn. Repeat this process until the upper filter is completely drained. 4. Close drain valves (3) and (4). Note: Dispose of used fluids according to local regulations. 5. Remove lower secondary filter (1). Note: The lower secondary filter has not been drained. The filter contains fuel. When you remove the lower filter, use caution in order to avoid spilling the fuel. 6. Inspect the fuel filter for debris by cutting the fuel filter open. Note: This fuel filter is a cartridge type filter. This type of filter cannot be reused.

Illustration 252

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8. Apply a thin coat of clean diesel fuel to the sealing surface of the new fuel filter. 9. Install the new fuel filter by hand. When the seal contacts the filter mounting base, tighten the filter by an additional 3/4 turn. The filter has rotation index marks that are spaced by increments of 1/4 turn. Use these rotation index marks as a guide for proper tightening.

10. Tighten upper secondary filter (2) in the same manner that is described in Step 9. 11. Prime the fuel system. See Operation and Maintenance Manual, “Fuel System Priming Pump - Operate” for instructions. 12. Close the engine hood and latch the engine hood.

305 Maintenance Section Fuel System Secondary Filter Number Two - Replace

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Fuel System Secondary Filter Number Two - Replace (Upper Filter) SMCS Code: 1261-510-SE

Personal injury or death can result from a fire. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.

Illustration 254

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Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system.

(1) Drain valve (2) Secondary filter (3) Drain valve

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

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

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

2. Open drain valve (3) and immediately open drain valve (1). Allow the fuel to drain into a suitable container. Note: Make sure that the drain valves are opened in the proper order. If you open the wrong drain valve first, an air lock in the fuel system may occur. This will not allow fuel to drain from the upper filter. 3. Slowly loosen upper secondary filter (2) for 1/4 turn. Allow any remaining fuel in the valves to drain into a suitable container. When the fuel stops draining, loosen upper secondary filter (2) for an additional 1/4 turn. Repeat this process until the upper filter is completely drained. 4. Close drain valves (3) and (1).

Illustration 253

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Note: Dispose of used fluids according to local regulations. 5. Remove upper secondary filter (2). 6. Inspect the fuel filter for debris by cutting the fuel filter open. Note: This fuel filter is a cartridge type filter. This type of filter cannot be reused. Note: Dispose of used filters according to local regulations. 7. Clean the mounting base of the fuel filter. Make sure that all of the old seal is removed from the mounting base.

306 Maintenance Section Fuel System Water Separator - Drain

i00796424

Fuel System Water Separator - Drain SMCS Code: 1263

Illustration 255

g00101318

8. Apply a thin coat of clean diesel fuel to the sealing surface of the new fuel filter. 9. Install the new fuel filter by hand. When the seal contacts the filter mounting base, tighten the filter by an additional 3/4 turn. The filter has rotation index marks that are spaced by increments of 1/4 turn. Use these rotation index marks as a guide for proper tightening.

Illustration 256

g00101429


10. Prime the fuel system. See Operation and Maintenance Manual, “Fuel System Priming Pump - Operate” for instructions. 11. Close the engine hood and latch the engine hood.

Illustration 257

g00104898

The water separator is located behind the left side access door at the back of the machine. The drain valve is located on the bottom of the water separator.

2. Turn the drain valve counterclockwise in order to open. Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on containing fluid spillage. 3. Drain the water and drain the sediment into a suitable container. Note: Dispose of drained fluids according to local regulations. 4. Close the drain valve.

307 Maintenance Section Fuel Tank Cap and Strainer - Clean

i00076547

Fuel Tank Cap and Strainer Clean SMCS Code: 1273-070-STR

Illustration 258

g00101392

1. Remove the fuel cap. 2. Inspect seal (4) for damage. Replace the seal, if necessary. 3. Remove screws (1), filter assembly (2), drain valve (3) and the gaskets.

Illustration 259

g00101393

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).

8. Install the fuel tank cap.

308 Maintenance Section Fuel Tank Water and Sediment - Drain

i00118500

Fuel Tank Water and Sediment - Drain

i00095100

Fuses - Replace SMCS Code: 1417-510

SMCS Code: 1273-543

Illustration 261 Illustration 260

g00101396

Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on containing fluid spillage. 1. Open the drain valve that is located under the fuel tank. 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.

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. Certain machines are equipped with electric refueling pumps. For more information, see Operation and Maintenance Manual, “Electric Refueling Pump”.

g00104892

The fuse panel is located on the left console. Open the access cover in order to access the fuses.

Fuses – Fuses protect the electrical system from damage that is caused by overloaded circuits. Change a fuse if the element separates. If the element of a new fuse separates, check the circuit and/or repair the circuit. NOTICE Always replace fuses with the same type and capacity fuse that was removed. Otherwise, electrical damage could result. NOTICE If it is necessary to replace fuses frequently, a electrical problem may exist. Contact your Caterpillar dealer. To replace a fuse, use the puller that is stored in the fuse panel. Two fuses of 10 Amperes, one fuse of 15 Amperes, and one fuse of 30 Amperes are contained in the fuse panel as spare fuses. The following list identifies the circuits that are protected by each fuse. The amperage for each fuse is included with each circuit.

309 Maintenance Section Fuses - Replace

Engine Start Switch (12) – 10 Amp Electric Refueling Pump (If Equipped) (13) – 30 Amp Fine Swing Control (14) – 10 Amp Boom Lamp (15) – 10 Amp Auto Lubricator (If Equipped) (16) – 10 Amp Switch Panel (17) – 10 Amp Cigar Lighter (18) – 10 Amp Heater and Air Conditioner (19) – 15 Amp Windshield Washer and Windshield Wiper (20) – 10 Amp Auxiliary Circuit (Attachment) (21) – 10 Amp Illustration 262

g00104894

Radio (If Equipped) (22) – 10 Amp Cab and Chassis Lamp (23) – 15 Auxiliary Hydraulic (Attachment) (24) – 15 Amp Spare (25) – 10 Amp Spare (26) – 15 Amp Spare (27) – 30 Amp

Illustration 263

g00104897

Spare (1) – 10 Amp Auxiliary Circuit (2) – 10 Amp Auxiliary Circuit (3) – 10 Amp Backup (4) – 10 Amp Inspection Lamp (If Equipped) (5) – 10 Amp Hydraulic Lock Limit Switch or Hydraulic Lock Solenoid (6) – 10 Amp Engine Governor (7) – 10 Amp Engine Controller or Pump Controller (8) – 15 Amp Horn (9) – 10 Amp Cab Dome Light(10) – 10 Amp

310 Maintenance Section Hydraulic System Bio Filter Element - Replace

i00731715

Hydraulic System Bio Filter Element - Replace (If Equipped) SMCS Code: 5068-510


g00326543

(1) Bolts (2) Cover

g00326545

(5) BIO filter element

3. Remove BIO filter element (5) from the filter assembly.

1. Remove seven bolts (1) and cover (2) from the machine.

4. Install a new filter element. 5. Place cover (4) in place and secure four bolts (3). 6. Place cover (2) in place and secure seven bolts (1).

Illustration 265

g00326544

(3) Bolts (4) Cover

2. Remove four bolts (3) and cover (4) from the BIO filter.

311 Maintenance Section Hydraulic System Bio Filter Pressure Gauge - Inspect

i00731972

Hydraulic System Bio Filter Pressure Gauge - Inspect (If Equipped) SMCS Code: 5068-040

Illustration 269

g00102191

6. Open the rear access door on the left side of the machine.

Illustration 267

g00101541

1. Slowly loosen the filler plug in order to relieve any pressure. 2. Tighten the filler plug after the pressure is relieved.

Illustration 270

g00101365

7. Open the front access door on the left side of the machine.

Illustration 268

g00101508

3. Place the machine in the servicing position, as shown. 4. Move the hydraulic activation control lever to the LOCKED position. 5. Turn the engine speed dial to the high idle position “10”.

Illustration 271

g00326654

312 Maintenance Section Hydraulic System Oil - Change

8. Read the value of the pressure gauge that is on top of the BIO filter. If the pressure is between “1 ± 0.2 bars” and “3 ± 0.2 bars”, the BIO filter element is clean. If the pressure is “3 ± 0.2 bars” or more, the BIO filter element is clogged. If this occurs, replace the BIO filter element. Refer to Operation and Maintenance Manual, “Hydraulic System Bio Filter Element - Replace” for information on replacing the BIO filter element.

i00722935

Hydraulic System Oil - Change SMCS Code: 5056-044 Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on Containing Fluid Spillage.

Illustration 272

g00101435

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

Illustration 273

g00102825

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

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


Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on Containing Fluid Spillage. 7. Remove the oil drain valve plug.

Illustration 274

g00101445

3. Clean the area thoroughly in order to keep dirt out of the screen cover. Clean the area thoroughly in order to keep dirt out of the fill/vent plug. 4. Relieve the internal pressure from the hydraulic tank by loosening the fill/vent plug. After the pressure is relieved, remove the fill/vent plug.

Illustration 277

g00293719

8. Install a Swivel Hose with clear plastic tubing in order to open the drain valve. Drain the oil into a suitable container. 9. Remove the Swivel Hose in order to close the drain valve. 10. Inspect the O-ring. Replace the O-ring if wear or damage is evident. 11. Clean the drain plug. Install the drain plug.

Illustration 275

g00101446

5. The oil drain valve is located under the hydraulic tank. 6. Remove the hydraulic tank access cover that is located under the upper structure. This will allow access to the drain valve. Illustration 278

g00101449

12. Open the access door on the right side of the machine. 13. Clean the pump. Clean the hydraulic lines. Clean the hydraulic tank.


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

Illustration 279

g00101450

14. Remove the plug from the tube. Allow the oil to drain into a container. 15. Inspect the O-ring. Replace the O-ring if wear or damage is evident. 16. Clean the plug. Install the plug and the O-ring into the drain port.

Illustration 281

g00101492

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

19. Remove O-ring seal (9) from the old screen. 20. Inspect O-ring seal (9) and O-ring seal (10). Replace the O-ring seals if wear or damage is evident. 21. Install O-ring seal (9) on new screen (8). 22. Install screen (8) and spring (7). Then, install cover (6), washers (5), and bolts (4). Note: Make sure that the O-ring seals and the spring are properly positioned during installation. Note: Perform the following five steps only if your machine is equipped with an auxiliary gear pump.

Illustration 280

g00101490

(4) Bolt (5) Washers (6) Cover (7) Spring (8) Screen

17. Remove bolts (4), washers (5), and cover (6). Note: Used filters and used fluids should always be disposed of according to established local regulations.

Illustration 282

g00107316

(11) Bolts (12) Washers (13) Plate

23. Remove four bolts (11) and four washers (12). Note: Do not allow spring (7) to fall into the tank.


24. Pull plate (13) away from the hydraulic tank. Inspect the seal on plate (13). Replace the seal if wear or damage is evident. 25. Remove the screen. Note: Used filters and used fluids should always be disposed of according to established local regulations. 26. Install a new screen. 27. Install four bolts (11) and four washers (12) in order to attach plate (13) to the hydraulic tank. 28. Fill the hydraulic system oil tank. Refer to Operation and Maintenance Manual, “Refill Capacities”. 29. Inspect the O-ring on the filler plug for damage. Replace the O-ring, if necessary. Clean the filler plug. Install the filler plug.

Illustration 285

g00101471

Note: Make no attempt to start the engine until the pump has been filled with hydraulic oil. Serious damage to the hydraulic components can result. 33. When the hydraulic oil has been replaced,the air must be removed from the hydraulic oil system. Use the following procedure to remove the air from the hydraulic oil system. a. While the engine is stopped, remove the vent plug which is on the top of the pump. Do not install the vent plug until the pump is filled with hydraulic oil. After the pump is filled with hydraulic oil, tighten the vent plug. Start the engine. When the engine is at low idle, fully raise the boom. Hold the boom in this position. b. Stop the engine. Slowly lower the boom until the bucket is on the ground. This pressurizes the hydraulic tank.

Illustration 283

g00101460

c. Slowly loosen the vent plug for several turns until the hydraulic oil flows out of the opening for the vent plug. This indicates that the air has been released from the pump. Tighten the plug.

30. Remove the pressure cap.

34. Close the access door. 35. Start the engine. Operate the engine at idling speed for five minutes.

Illustration 284

g00101462

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

316 Maintenance Section Hydraulic System Oil Filter - Replace

i00095013

Hydraulic System Oil Filter Replace SMCS Code: 5068-510

Replace the Pilot Filter

Illustration 286

g00101435

36. Operate the control levers in order to circulate the hydraulic oil. Lower the bucket to the ground so that the stick is vertical to the ground. Stop the engine.

Illustration 288

g00101497

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

Illustration 287

g00101475

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

37. Maintain the oil level between the marks on the sight gauge in the appropriate temperature range. Illustration 289

g00104889

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. Note: Used filters should always be disposed of according to local regulations. 4. Clean the filter base.

317 Maintenance Section Hydraulic System Oil Filter - Replace

2. Remove the used case drain filter from the filter base. Note: This element is a cartridge type filter. The element cannot be reused. Note: Used filters should always be disposed of according to local regulations. 3. Clean the filter base.

Illustration 290

g00101502

5. Coat the seal of a new pilot filter with clean hydraulic oil. Install the new pilot filter in the filter base. Tighten the pilot filter hand tight. 6. Close the access door.

Replace the Case Drain Filter Illustration 293

g00101502

4. Coat the seal of a new case drain filter with clean hydraulic oil. Install the new case drain filter in the filter base. Tighten the case drain filter hand tight. 5. Drive the machine slowly for 10 to 15 minutes. Move each cylinder evenly through several cycles.

Illustration 291

g00101504

The case drain filter is located on the side of the fuel tank.

Illustration 294

g00101508

6. Return the machine to the position that is shown above. Check the machine for oil leaks. 7. Stop the engine. Illustration 292

g00101507

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

8. Open the access door on the right side of the machine in order to access the sight gauge.

318 Maintenance Section Hydraulic System Oil Level - Check

Note: On the 320B Excavator, the sight gauge is on the side of the machine. The access door does not need to be opened.

i00790351

Hydraulic System Oil Level Check SMCS Code: 5050-535 NOTICE Never remove the fill/vent plug from the hydraulic tank if the oil is hot. Air can enter the system and cause pump damage. Note: The hydraulic oil tank is on the right side of the machine.

Illustration 295

g00104886

1. Park the machine on level ground.

(A) High Temperature Range. (B) Low Temperature Range.

9. 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.

Illustration 297

g00101347

Excavator Position the machine with the stick in the vertical position and the implement on the ground.

Illustration 296

g00101541

10. Slowly loosen the filler plug in order to relieve any pressure. Remove the filler plug in order to add oil, if necessary. 11. Clean the filler plug. Install the filler plug. 12. Close the access door.

Illustration 298

g00368266

Excavator with VA boom Retract the stick cylinder. Extend the boom cylinders. Place the bucket on the ground.

319 Maintenance Section Hydraulic System Oil Level - Check

Illustration 301

g00368333

Coal shovel Position the bucket on the ground and position the bucket as close as possible to the machine.

Illustration 299

g00368271

2. Position the machine in a position that is shown in illustration 297, 298, 299, 300, or 301.

Super long demolition Completely raise the boom and position the tool as close as possible to the machine.

Illustration 302

Illustration 300

g00270080

g00101524

3. Open the access door on the right side of the machine.

Material handler Completely raise the boom and fully retract the stick cylinder.

Illustration 303 (A) High temperature range (B) Low temperature range

g00104886

320 Maintenance Section Hydraulic System Oil Return Filter - Replace

Note: On the 320B Excavator, the sight gauge is on the side of the machine. The access door does not need to be opened. 4. For a cold machine, maintain the hydraulic oil level in the low temperature range. For a machine that is at normal operating temperature, maintain the hydraulic oil level in the high temperature range.

i00693713

Hydraulic System Oil Return Filter - Replace SMCS Code: 5068-510-RJ

Remove the Filter Cartridge The return filter is a cartridge type filter. The return filter reduces the amount of foreign material that enters the hydraulic system when the filter element is replaced.

Illustration 304

g00101541

Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information about containing fluid spillage. Note: Perform Step 5 through Step 7 if the oil level is low. 5. Slowly loosen the filler plug in order to relieve any pressure. Add oil, if necessary. 6. Check the O-ring seal on the filler plug. Replace the O-ring seal if the O-ring seal is damaged.

Illustration 305

g00102209

Note: If the indicator for a Restricted Hydraulic Return Filter comes on, push the reset switch at the filter case. Run the machine on level ground for approximately 10 minutes. If the indicator still comes on, inspect the filter and replace the filter, if necessary.

7. Clean the filler plug and install the filler plug. 8. Close the access door.

Illustration 306

g00104900

1. Loosen the filler plug in order to relieve the hydraulic tank pressure. Tighten the filler plug after the hydraulic tank pressure is relieved. Note: The return filter is located behind the filler plug.


Illustration 307

g00102211

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

Illustration 309

g00102214

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

2. Remove bolts (1), washers (2), and cover (3). Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on Containing Fluid Spillage. 3. Remove plug (4) in order to release the pressure in filter cartridge (5).

Illustration 310

g00102219

(7) O-ring.

6. Inspect the cover and O-ring (7). If either part is damaged, replace the part. 7. Inspect the filter cartridge for debris and for damage. If necessary, replace the filter cartridge. Illustration 308

g00102212

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

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


Remove the Filter Element


g00104507

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

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

g00104510

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

3. Hold the filter cartridge with one hand. Grasp the grip of plate (8) with your other hand. Lift plate (8) in order to separate plate (8) from the filter cartridge. 4. Remove O-ring (11) from plate (8). 5. Lift filter element (12) from shell (10). 6. Pour the remaining oil into a suitable container.

Clean Shell of Filter Cartridge

Illustration 312

g00104508

(8) Plate (9) Spiral retaining ring

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

Illustration 314

g00104511

(13) Slide plate (14) Pads (15) Screws (19) Port

1. Turn shell (10) upside-down. 2. Remove screws (15). 3. Remove Pads (14) from slide plate (13). 4. Wash the following parts in a clean nonflammable


Install the Filter Element

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. 1. Spray oil to the inside of shell (10) in order to prevent rust. 2. Apply grease to a new O-ring (11). 3. Plate (8) will contact the inside of shell (10). Apply grease to this point. 4. Apply grease to O-rings inside ports (19) at the bottom of shell (10). Illustration 316

g00102220

5. Install new Pads (14). Tighten the screws to a torque of 0.4 N·m (3.5 lb in).

(B) Port (C) Slide plate

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

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

Illustration 315

g00104512

(8) Plate (10) Shell (16) Boss (17) Notch

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

Illustration 317

g00102221

(E) Slide plate (D) Port

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

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

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

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.

10. Apply grease to new O-ring (18). Install O-ring (18) on plug (4). 11. Install plug (4) into plate (8).


6. To turn off the indicator for a Restricted Hydraulic Return Filter, push the reset switch on the filter case while the engine start switch is in the ON position.

Illustration 318

g00102222

(F) O-rings

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

Illustration 319

g00102225

(1) Bolts

4. Install the filter cartridge into the filter case. Turn the filter cartridge clockwise by 1/2 turn and push down the filter cartridge when the filter cartridge contacts guide (A). 5. 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).

325 Maintenance Section Hydraulic System Oil Sample - Obtain

i00914176

Hydraulic System Oil Sample - Obtain

i00107754

Indicators and Gauges - Test SMCS Code: 7450-081; 7490-081

SMCS Code: 5050-008; 7542-008


g00101628

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

g00106777

1. Look for broken lenses on the gauges, broken indicator lights, broken switches, and other broken components in the cab. 2. Start the engine. 3. Look for inoperative gauges. 4. Turn on all machine lights. Check for proper operation. 5. Move the machine forward. Release the travel levers and the travel pedals. The machine should stop. 6. Stop the engine.

Illustration 322

g00274522

The hydraulic oil sampling valve is located near the pilot filter. Refer to Operation and Maintenance Manual, “S·O·S Oil Analysis” for more information on obtaining a hydraulic oil sample.

7. Make any repairs that are required before operating the machine.

326 Maintenance Section Oil Filter - Inspect

i00052234

i00094899

Oil Filter - Inspect

Quick Coupler - Lubricate

SMCS Code: 1308-507; 5068-507

SMCS Code: 6129-086

Inspect A Used Filter for Debris


Illustration 324

g00100013

The element is shown with debris.

Use a 4C-5084 Filter Cutter to cut the filter element open. Spread apart the pleats and inspect the element for metal and for other debris. An excessive amount of debris in the filter element can indicate a possible failure. If metals are found in the filter element, a magnet can be used to differentiate between ferrous metals and nonferrous metals. Ferrous metals can indicate wear on steel parts and on cast iron parts. Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings, rod bearings, or turbocharger bearings. Small amounts of debris may be found in the filter element. This could be caused by friction and by normal wear. Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found. Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings, to the crankshaft, and to other parts. This can result in larger particles in unfiltered oil. The particles could enter the lubricating system and the particles could cause damage.

Illustration 325

g00104878

Apply lubricant through the four fittings on the quick coupler. The quick coupler has two fittings on each side.

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

327 Maintenance Section Radiator Core - Clean

i00118496

Radiator Core - Clean

i00734932

Refueling Pump Strainer Clean (If Equipped)

SMCS Code: 1353-070

SMCS Code: 1295-070-STR

Illustration 326

g00101559

(1) Wing bolt (2) Radiator screen

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

Illustration 328 (1) (2) (3) (4) (5)

g00103385

Suction hose Clamp Strainer Bar Strip

1. Open the cover for the storage box on the front of the machine. 2. Remove suction hose (1) from the holder. Illustration 327

g00101560

2. Check the radiator fins for debris. 3. Remove dust and debris from the radiator fins and from the radiator screen. Compressed air is preferred, but high pressure water or steam can be used to remove dust and general debris from the radiator. Clean the radiator according to the condition of the radiator. See Special Publication, SEBD0518, “Know Your Cooling System” for more detailed information about cleaning radiator fins.

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

3. Loosen clamp (2) and disconnect strainer (3) from hose (1). 4. Wash strainer (3) in a clean, nonflammable solvent. Allow the strainer to dry. 5. Mount strainer (3) on suction hose (1). 6. Secure the strainer and the hose with clamp (2). NOTICE To prevent hose damage, do not coil the hose in a tight radius. 7. When suction hose (1) is stored, wind the suction hose on bar (4) that is provided in the storage box. Hold the hose end with strip (5), as shown. 8. Close the cover for the storage box.

328 Maintenance Section Seat Belt - Inspect

i00112638

i00731002

Seat Belt - Inspect

Seat Belt - Replace

SMCS Code: 7327-040

SMCS Code: 7327-510

Illustration 329

g00101563

When this machine was shipped from Caterpillar, Inc., this machine was equipped with a seat belt and with a seat belt installation. At the time of installation, the seat belt and the seat belt installation met “SAE J386 JUN85” for an industrial machine and “SAE J386 JUN93”. Consult your Caterpillar dealer for all replacement parts. Regardless of appearance, replace the seat belt after every three years of use. A date label for determining the age of the seat belt is attached to each seat belt. Always check the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine. If damage or wear is found, replace either the seat belt or the seat belt mounting mounting hardware hardware before before operating operating the machine. machine.

Illustration 330

g00037721

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

329 Maintenance Section Swing Bearing - Lubricate

i00059356

i00093759

Swing Bearing - Lubricate

Swing Drive Oil - Change

SMCS Code: 7063-086

SMCS Code: 5459-044

Wipe the fittings before you lubricate the swing bearings.

Illustration 333

Illustration 331

g00101569

g00101586

The oil drain hose is under the center of the upper structure.

The swing bearings are under the base of the boom.


g00101570

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

g00101591

Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information about containing fluid spillage. 1. Remove drain hose (2) from holder (1) on the upper frame. Face the end of the hose toward the container. 2. Use a universal joint with a socket extension to loosen the drain valve in hole (3). Drain the oil into a suitable container. Note: Drained fluids should always be disposed of according to local regulations.

330 Maintenance Section Swing Drive Oil Level - Check

i00093757

Swing Drive Oil Level - Check SMCS Code: 5459-535-FLV

Illustration 335

g00101600

3. Tighten the drain valve. Hook drain hose (2) to holder (1). Make sure that the end of the hose is facing upward. Illustration 337

g00101622

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

Illustration 336

g00104863

4. Remove dipstick (4). 5. Add the specified quantity of oil through the dipstick tube. See Operation and Maintenance Manual, “Refill Capacities”.

Illustration 338

g00104861

1. Remove the dipstick.

6. Make sure that the oil level is maintained to the “FULL” mark on dipstick (4).

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

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

2. Check the dipstick. Maintain the oil level to the “FULL” mark on the dipstick. Add oil through the dipstick tube, if necessary.

Note: Drained materials should always be disposed of according to local regulations.

3. Insert the dipstick.

331 Maintenance Section Swing Drive Oil Sample - Obtain

i00858525

Swing Drive Oil Sample Obtain SMCS Code: 5459-008 Refer to Operation and Maintenance Manual, “S·O·S Oil Analysis” for information that pertains to obtaining a sample of the swing drive oil. Obtain a sample of the swing drive oil through the opening of the dipstick.

i00093750

Swing Gear - Lubricate SMCS Code: 7063-086 NOTICE When the amount of grease in the compartment becomes 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.

Illustration 339

g00101649

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

Illustration 340

g00101728

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

332 Maintenance Section Swing Gear - Lubricate

Illustration 341

g00101652

Illustration 343

g00101654

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

6. Raise the boom and turn the upper structure by 30 degrees. Lower the bucket to the ground.

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

7. Repeat Step 3 at every 30 degrees in 12 places. Add grease, as needed.

The depth of the grease should be 13 to 19 mm (0.50 to 0.75 inch). The capacity of the pan is 21.2 L (5.6 US gal) or 19.3 kg (42.5 lb). Add grease, as needed. Remove grease, as needed. Too much grease will result in the deterioration of the grease because of excessive movement of the grease. Too little grease will result in poor lubrication of the swing gear.

Illustration 342

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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 reinstall plug (5), inspect O-ring seal (6). Replace the O-ring seal if damage is evident.

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

333 Maintenance Section Swing Out Hydraulic Oil Cooler - Clean

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Swing Out Hydraulic Oil Cooler - Clean (If Equipped) SMCS Code: 1374-070 The swing out hydraulic oil cooler makes cleaning the radiator and the hydraulic oil cooler easier.

Illustration 346

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(6) Hydraulic oil cooler (7) Radiator

4. Check for accumulated dust in the fins of hydraulic oil cooler (6) and radiator (7).

Illustration 344

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(1) Bolts (2) Washers (3) Support

1. Open the engine hood and open the access door on the left side of the machine. 2. Remove bolts (1) and washers (2) (4 positions), and open support (3).

Illustration 345

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(4) Bolts (5) Washers (6) Hydraulic oil cooler

3. Remove bolts (4) and washers (5) (4 positions), and tilt hydraulic oil cooler (6) outward.

5. Clean the fins of the hydraulic oil cooler and radiator with compressed air, pressurized water or steam. At the same time, clean the screen that is attached to the radiator. 6. After cleaning, tilt hydraulic oil cooler (6) and support (3) upward. When hydraulic oil cooler (6) and support (3) are back into position, tighten the bolts to a torque of 100 ± 20 N·m (75 ± 15 lb ft). Note: Refer to Operation and Maintenance Manual, “Radiator Core - Clean” for information on cleaning the radiator core.

334 Maintenance Section Track Adjustment - Adjust

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Tightening the Track

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 pressure can penetrate the body causing injury or death. Do not watch the relief valve to see if grease is escaping. Watch the track or track adjustment cylinder to see if the track is being loosened.

Illustration 348

Loosen the relief valve one turn only.

Wipe the fitting before you add grease.

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The track adjuster is located on the track frame.

If track does not loosen, close the relief valve and contact your Caterpillar dealer. NOTICE Keeping the track properly adjusted will increase the service life of the track and drive components. Note: The track tension must be set according to the current operating conditions. Keep the track as slack as possible if the soil is heavy.

Measuring Track Tension Illustration 349

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1. Add grease through valve fitting (1) until the correct track tension is reached. 2. Operate the machine back and forth in order to equalize the pressure. 3. Check the amount of sag. Adjust the track, as needed.

Illustration 347

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1. Place a straight edge on the tracks. The straight edge should be long enough to extend from the idler to the carrier roller. 2. Measure the maximum amount of sag in the track. The sag is measured from the highest point of the track grouser to the bottom of the edge. A track that is properly adjusted will have

335 Maintenance Section Track Adjustment - Inspect

Loosening the Track

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Track Adjustment - Inspect SMCS Code: 4170-040

Illustration 350

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The track adjuster is located on the track frame. Illustration 352

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Check the track adjustment. Check the track for wear and for excessive dirt buildup. If the track appears to be too tight or too loose, see Operation and Maintenance Manual, “Track Adjustment - Adjust”.

Illustration 351

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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 N·m (25 lb ft) when the desired track tension is reached. 3. Operate the machine back and forth in order to equalize the pressure. 4. Check the amount of sag. Adjust the track, as needed. If the correct adjustment cannot be achieved, consult your Caterpillar dealer.

336 Maintenance Section Travel Alarm - Test

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Travel Alarm - Test SMCS Code: 7429-081 You must move the machine in order to test the travel alarm.

1. Start the engine. Move the hydraulic activation control lever to the UNLOCKED position. 2. Raise the attachments in order to avoid any obstacles. Make sure that there is adequate overhead clearance.

Illustration 353

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3. Use the travel levers or the travel pedals to move the machine forward. The travel alarm should sound. 4. Release the travel levers and the travel pedals in order to stop the machine. 5. Use the travel levers and the travel pedals to move the machine backward. The travel alarm should sound.

Illustration 354

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6. Push the alarm cancel switch that is located on the electronic monitor panel. The travel alarm

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

337 Maintenance Section Undercarriage - Check

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Undercarriage - Check

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V-Belts - Inspect/Adjust/ Replace

SMCS Code: 4150-535

SMCS Code: 1357-025; 1357-040; 1357-510; 1359-025; 1359-040; 1359-510; 1361-025; 1361-040; 1361-510; 1405-025; 1405-040; 1405-510; 7320-025; 7320-040; 7320-510

Illustration 355

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1. Check the carrier rollers, the track rollers, and the idler wheels for possible leakage. 2. Check the surface of the track, the carrier rollers, the track rollers, the idler wheels, the track shoes, and the drive sprockets. Look for signs of wear and loose mounting bolts. 3. Listen for any abnormal noises while you are moving slowly in an open area.

Your engine can be equipped with a water pump belt, with a fan drive belt and with accessory drive belts. Your engine can also be equipped with an alternator belt. For maximum engine performance and maximum utilization of your engine, inspect the belts for wear and for cracking. Check the belt tension. Adjust the belt tension in order to minimize belt slippage. Belt slippage will decrease the belt life. Belt slippage will also cause poor performance of the alternator and of any driven equipment. If new belts are installed, recheck the belt adjustment after 30 minutes of operation. If two belts or more are required for an application, replace the belts in belt sets. If only one belt of a matched set is replaced, the new belt will carry more load. This is due to the fact that the older belts are stretched. The additional load on the new belt could cause the new belt to break.

Water Pump Belt

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

Illustration 356

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1. To check the belt tension, apply 110 N (25 lb) of force midway between the pulleys. Correctly adjusted belts will deflect 13 to 19 mm (1/2 to 3/4 inch).

338 Maintenance Section V-Belts - Inspect/Adjust/Replace

Illustration 357

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Typical example

Illustration 359

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

(1) Mounting bolt (2) Bracket bolt (3) Idler pulley (4) Square hole

2. To adjust the water pump drive belt, loosen mounting bolt (1) and bracket bolt (2).

2. To adjust the alternator belt and the fan belt, loosen bracket bolt (1) and mounting bolt (2) on the alternator bracket.

3. Move idler pulley (3) in order to achieve the correct adjustment.

3. To achieve the correct adjustment, move the alternator inward or move the alternator outward, as required.

4. If necessary, use a pry bar in square hole (4) in the mounting bracket.

4. If necessary, use a pry bar in hole (3) in the alternator bracket.

5. Tighten mounting bolt (1) and bracket bolt (2).

5. Tighten mounting bolt (2) and bracket bolt (1).

6. If a new belt is installed, run the engine at rated speed for thirty minutes. Check the bolt torque. Readjust the belt, if necessary.

Note: The alternator shaft nut must be tightened to a torque of 50 ± 5 N·m (37 ± 4 lb ft). 6. If new belts are installed, check the belt adjustment again after 30 minutes of engine operation at the rated speed.

Alternator Belt and Fan Belt

Air Conditioner Belt NOTICE The V-belt must be tensioned correctly. Failure to tension the belt properly could cause damage to the belt and/or to the air conditioner compressor.

Illustration 358

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1. To check the belt tension, apply 110 N (25 lb) of force midway between the pulleys. Correctly adjusted belts will deflect 13 to 19 mm (1/2 to 3/4 inch).

339 Maintenance Section Walk-Around Inspection

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Walk-Around Inspection SMCS Code: 7000 NOTICE Accumulated grease and oil on a machine is a fire hazard. Remove debris with steam cleaning or high pressure water, at the specified interval in the Maintenance Interval Schedule or each time any significant quantity of oil is spilled on the machine. Illustration 360

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1. Apply approximately 98 N (22 lb) force midway between the pulleys.

Illustration 361

Note: Watch closely for leaks. If you observe a leak, find the source of the leak and correct the leak. If you suspect a leak or you observe a leak, check the fluid levels more frequently.

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(1) Nut (2) Bolt (3) Bolt

Illustration 362

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2. Measure the deflection of the belt. The belt should deflect 7 to 10 mm (5/16 to 7/16 inch).

Inspect the hydraulic cylinders for damage or for excessive wear. Inspect the linkage and the bucket for damage or for excessive wear. Make any necessary repairs.

3. If the deflection is not correct, loosen nut (1) and two bolts (2). Turn bolt (3) in order to adjust the belt tension.

Inspect the lights for broken bulbs and for broken lenses. Replace any broken bulbs and any broken lenses.

4. When the adjustment is correct, tighten nut (1) and two bolts (2) to a torque of 100 ± 20 N·m (70 ± 15 lb ft).

Inspect the engine compartment for any trash buildup. Remove any trash buildup from the engine compartment.

5. Check the deflection again.

Inspect the cooling system for any leaks, for faulty hoses and for any trash buildup. Correct any leaks. Remove any trash from the radiator.

Note: If a new belt is installed, check the belt adjustment again after 30 minutes of engine operation at the rated speed.

Inspect all of the belts for the engine attachments. Replace any belts that are worn, frayed, or broken.

340 Maintenance Section Walk-Around Inspection

Adjust the rearview mirrors for the best operator vision.

Illustration 363

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Inspect the hydraulic system for leaks. Inspect the tank, the cylinder rod seals, the hoses, the tubes, the plugs, the connections, and the fittings. Correct any leaks in the hydraulic system. Inspect the final drives for leaks. Make any necessary repairs. Check the oil level if leakage is noticed. Inspect the swing drive for leaks. Make any necessary repairs. Make sure that all covers and guards are securely attached. Inspect the covers and the guards for damage.

Illustration 364

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Inspect the steps, the walkways, and the handholds. Clean the steps, the walkways, and the handholds. Make any necessary repairs. Inspect the Falling Objects Protective Structure for damage. If repair is necessary, consult your Caterpillar dealer. Tighten any loose bolts. Inspect the operator compartment for trash buildup. Check for trash buildup under the floorplate. Keep these areas clean.

341 Maintenance Section Windows - Clean

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Windows - Clean SMCS Code: 7310-070; 7340-070 Use commercially available window cleaning solutions in order to clean the windows. Clean the outside of the windows from the ground, unless handholds are available.

Cleaning Methods

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Windshield Washer Reservoir Fill SMCS Code: 7306-544-KE NOTICE When operating in freezing temperatures, use Caterpillar or any commercially available nonfreezing window washer solvent.

Aircraft Windshield Cleaner Apply the cleaner with a soft cloth. Rub the window with moderate pressure until all the dirt is removed. Allow the cleaner to dry. Wipe off the cleaner with a clean soft cloth.

Soap and Water Use a clean sponge or a soft cloth. Wash the windows with a mild soap or with a mild detergent. Also use plenty of lukewarm water. Rinse the windows thoroughly. Dry the windows with a moist chamois or with a moist cellulose sponge.

Illustration 365

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Stubborn Dirt and Grease

The windshield washer reservoir is located behind the cab.

Wash the windows with a good grade of naphtha, or isopropyl alcohol, or of Butyl Cellosolve. Then, wash the windows with soap and with water.


Illustration 366 Typical example

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320B, 322B and 325B Excavators-Maintenance Intervals

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