Https Safety.cat.Com Cda Files 2454527 7 SEBU8301-02 M

8/10/2019 Https Safety.cat.Com Cda Files 2454527 7 SEBU8301-02 M

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2010 CaterpillarAll Rights Reserved

MAINTENANCE INTERVALSOperation and MaintenanceManual Excerpt


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SEBU8301-02June 2010

Operation andMaintenance

Manual390D Excavator

WAG1-Up (Machine)BYP1-Up (Machine)WAP1-Up (Machine)WBT1-U p (Machine)

KCZ1-Up (Machine)

SAFETY.CAT.COM


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SEBU8301-02 257Maintenance Section

Maintenance Interval Schedule

i03984417

Maintenance Interval ScheduleSMCS Code: 7000

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

The user is responsible for the performance of maintenanc e, including all adjustments, the use of proper lubricants, uids, lters, and the replacementof components due to normal wear and aging. Failureto adhere t o proper maintenance intervals andprocedures may result in diminished performance of the product and/or accelerated wear of components.

Use mileage, fuel consumption, service hours, or

calendar time, WHICH EVER OCCURS FIRST,in order t o determine the maintenance intervals.Products that operate in severe operating conditionsmay require more frequent maintenance.

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

Note: If Cat HYDO Advanced 10 hydraulic oil isused, th e hydraulic oil change interval is 3000 servicehours. SOS services may extend the oil change to alonger interval. Consult your Cat dealer for details.

When Re quired Air Conditioner/Cab Heater Filter (Recirculation) -

Inspe ct/Replace ................................................ 259Battery - Recycle ................................................ 259Battery or Battery Cable - Inspect/Replace ........ 259Bucke t Linkage - Inspect/Adjust ......................... 262Bucket Tips - Inspect/Replace ............................ 263Cab Air Filter (Fresh Air) - Clean/Replace .......... 266Came ra - Clean/Adjust ....................................... 266Circuit Breakers - Reset ...................................... 268Counterweight Removal Chain - Clean .............. 273Engi ne Air Filter Primary Element - Clean/

Replace ............................................................. 274

Engine Air Filter Secondary Element - Replace .. 277Eng ine Air Precleaner - Clean ............................ 277Ether Starting Aid Cylinder - Replace ................. 282Fuel System - Prime ........................................... 284Fus es - Replace .................................................. 287High Intensity Discharge Lamp (HID) - Replace .. 289Hydraulic Tank Screen - Clean ........................... 300Oil Filter - Inspect ................................................ 302Radiator Core - Clean ......................................... 303Track Adjustment - Adjust ................................... 309Window Washer Reservoir - Fill ........................... 311Window Wiper - Inspect/Replace ........................ 312Window - Check .................................................. 312Windows - Clean ................................................. 312

Every 10 Servic e Hours or Daily for First 100Hours

Boom, Stick and Bucket Linkage - Lubricate ...... 260

Every 10 Servi ce Hours or Daily

Cooling System Coolant Level - Check .............. 271Engine Oil Le vel - Check .................................... 278Fuel System Water Separator - Drain ................. 286Fuel Tank Water and Sediment - Drain ............... 287Hydraulic S ystem Oil Level - Check ................... 300Indicators and Gauges - Test .............................. 302Seat Belt - Inspect .............................................. 304Track Adjus tment - Inspect ................................. 310Travel Alarm - Test .............................................. 310Undercarriage - Check ......................................... 311

Every 10 Se rvice Hours or Daily for MachinesUsed in Sev ere Applications


Every 50 S ervice Hours or Weekly


Every 10 0 Service Hours of ContinuousHammer U se

Hydraulic System Filter Element (Fine Filtration) -Replac e ............................................................. 290

Hydraulic System Oil Filter (Case Drain) -Replace ............................................................. 293

Hydrau lic System Oil Filter (Pilot) - Replace ....... 295

Initial 250 Service Hours

Engin e Valve Lash and Fuel Injector Timing -Check ................................................................ 281

Final Drive Oil - Change ..................................... 282Hydra ulic System Filter Element (Fine Filtration) -

Replace ............................................................. 290Hydraulic System Oil Filter (Case Drain) -

Repl ace ............................................................. 293Hydraulic System Oil Filter (Pilot) - Replace ....... 295Hydraulic System Oil Filter (Return) - Replace ... 296Swin g Drive Oil - Change ................................... 305

Every 250 Service Hours

Coo ling System Coolant Sample (Level 1) -Obtain ............................................................... 272

Counterweight Removal Chain - Inspect ............ 273Eng ine Oil Sample - Obtain ................................ 279Final Drive Oil Sample - Obtain .......................... 283

Every 250 Service Hours for Machines Usedin Severe Applications

Fuel System Primary Filter (Water Separator)Element - Replace ............................................ 284


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258 SEBU8301-02Maintenance SectionMaintenance Interval Schedule

Every 250 Servi ce Hours or Monthly

Belt - Inspect/Adjust/Replace .............................. 260Condenser (Re frigerant) - Clean ........................ 268Final Drive Oil Level - Check .............................. 283Swing Bearing - Lubricate ................................... 304

Swing Drive Oi l Level - Check ............................ 306

Every 250 Service Hours of Partial Hammer Use (50% of Service Hours)

Hydraulic S ystem Filter Element (Fine Filtration) -Replace ............................................................. 290

Hydraulic System Oil Filter (Case Drain) -Replace ............................................................. 293

Hydraulic System Oil Filter (Pilot) - Replace ....... 295

Every 250 Service Hours of ContinuousHammer Use

Hydraulic System Oil Filter (Return) - Replace ... 296

Initial 500 Hours (for New Systems, Re lledSystems, and Converted Systems)

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 273

Every 50 0 Service Hours

Hydraulic System Oil Sample - Obtain ............... 300Swing D rive Oil Sample - Obtain ........................ 307

Every 500 Service Hours or 3 Months

Engine Crankcase Breather - Clean ................... 278Engine Oil and Filter - Change ........................... 279Fuel System Primary Filter (Water Separator)

Eleme nt - Replace ............................................ 284Fuel System Secondary Filter - Replace ............ 285Fuel Tank Cap and Strainer - Clean ................... 286Hydra ulic System Filter Element (Fine Filtration) -

Replace ............................................................. 290Hydraulic System Oil Filter (Case Drain) -

Repl ace ............................................................. 293Hydraulic System Oil Filter (Pilot) - Replace ....... 295

Every 500 Service Hours of Partial Hammer

Use (50% of Service Hours)Hydraulic System Oil Filter (Return) - Replace ... 296

Every 600 Service Hours of ContinuousHammer Use

Hydraulic System Oil - Change ........................... 290


Battery - Clean .................................................... 259Battery Hold-Down - Tighten ............................... 259Counterweight Removal Chain - Lubricate ......... 274Hydraulic System Oil Filter (Return) - Replace ... 296

Swing Drive Oil - Change ................................... 305

Every 1000 Service Hours of Partial Hammer Use (50% of Service Hours)

Hydraulic Sys tem Oil - Change ........................... 290

Every 2000 Service Hours or 1 Year

Engine Valve Lash and Fuel Injector Timing -Check ................................................................ 281

Engine Valve Rotators - Inspect ......................... 281Final Drive Oil - Change ..................................... 282Receiver Dryer (Refrigerant) - Replace .............. 303Swing Gear - Lubricate ....................................... 308

Every Year

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 273


Hydrauli c System Oil - Change ........................... 290

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

Seat Bel t - Replace ............................................. 304

Every 6000 Service Hours or 3 Years

Coolin g System Coolant Extender (ELC) - Add .. 270

Every 12 000 Service Hours or 6 Years

Cooli ng System Coolant (ELC) - Change ........... 269


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Air Conditioner/Cab Heater Filter (Recirculation) - Inspect/Replace

i02459073

Air Conditioner/Cab Heater Filter (Recir culation) -Inspect/ReplaceSMCS Code: 10 54-040-A/C; 1054-510-A/C

NOTICE An air recirculation lter element plugged with dust willresult in decreased performance and service life to theair conditioner or cab heater.

To prevent decreased performance, clean the lter el-ement, as required.

g01100988Illust ration 275

The air conditioner

lter is located on the lower leftside o f the cab behind the seat.

1. Slide the operator seat forward.

2. Slide the lter element upward.

3. Tap t he air lter in order to remove the dirt. Do notuse compressed air to clean the lter.

4. After you clean the lter element, inspect the lter element. If the lter element is damaged or badlycontaminated, use a new lter element. Make suretha t the lter element is dry.

5. Install the lter element.

i00934864

Battery - CleanSMCS Code: 1401-070

Clean the battery surface with a clean cloth. Keep theterminals clean and keep the terminals coated withpetroleum jelly. Install the post cover after you coatthe terminal post with petroleum jelly.

i00993589

Battery - RecycleSMCS Code: 1401-561

Always recycl e a battery. Never discard a battery. Always return used batteries to one of the followinglocations:

A battery supplier

An authorized battery collection facility

Recycling facility

i00934872

Battery Hold-Down - TightenSMCS Code: 7257

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

i01913589

Battery or Battery Cable -Inspect/ReplaceSMCS Code: 1401-040; 1401-510; 1401-561; 1401;

1402-040; 1402-510

Pers onal injury can result from battery fumes or explosion.

Bat teries give off ammable fumes that can ex-plode. Electrolyte is an acid and can cause per-sonal injury if it contacts the skin or eyes.

Prevent sparks near the batteries. Sparks couldcause vapors to explode. Do not allow jumper ca-

bl e ends to contact each other or the engine. Im-proper jumper cable connections can cause an ex-plosion.

Always wear protective glasses when workingwith batteries.

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

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


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260 SEBU8301-02Maintenance SectionBelt - Inspect/Adjust/Replace

3. Disconnect the negative battery cable at thebattery.

4. Disconnect th e positive battery cable at thebattery.

5. Disconnect t he battery cables at the batterydisconnect switch. The battery disconnect switchis connected to the machine frame.

6. Make necessary repairs or replace the battery.

7. Connect the battery cable at the battery disconnectswitch.

8. Connect th e positive battery cable of the battery.

9. Connect the negative battery cable of the battery.

10. Install the key and turn the battery disconnectswitch to the ON position.

i02235410

Belt - Inspect/Adjust/ReplaceSMCS Cod e: 1357-025; 1357-040; 1357-510;

1397-025; 1397-040; 1397-510

Note: This engine is equipped with a belt tightener that automatically adjusts the belt to the correcttension.

1. Unlatch the engine hood and raise the enginehood.

2. Inspect the belt for wear and for cracking.

3. If the belt requires replacement, perform Step 3.athrough Step 3.c.

g01127241Illustration 276

a. Turn the belt tensioner in order to release thetension from the belt.

b. Remove the belt.

c. Install a new belt.

4. Close the engine hood.

i03865613

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

Note: Caterpillar recommends the use of 5%molybdenum grease for lubricating the boom,stick, and bucket linkage. Refer to SpecialPublication, SEBU6250, Caterpillar MachineFluids Recommendations for more information onmolybdenum grease.


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Boom, Stick and Bucket Linkage - Lubricate


Wipe all ttings before you apply lubricant.


1. Apply lubricant through the tting at the base of each b oom cylinder.


2. The ttings are at the base of the boom. The ttings can be serviced from the platform on thestorage box. To lubricate the lower boom bearings,apply lubricant through ttings (1) and (2). Tolubricate the boom cylinder rod, apply lubricantthrough ttings (3) and (4). To lubricate the stickcylinder head, apply lubricant through tting (5).

Note: To ensure proper lubrication of the lower boombearings and of the boom cylinder rod end bearings,lubricant should be applied through ttings (1), (2),(3), and (4). A pply lubricant rst when the boom israised and any work tool is suspended. Then applylubricant when the boom is lowered and the work

tool is reste d on the ground with a slight downwardpressure.

g013968 56Illustration 280

3. Apply lubricant through ttings (6) and (7). These ttings are on the bucket.

4. Apply lubricant through ttings (8) and (9). These ttings are on the stick.

5. Apply lubricant through ttings (10), (11), and (12).These ttings are on the link.


6. Apply lubricant through tting (13). Fitting (13) is atthe connection point of the boom and of the stick.


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262 SEBU8301-02Maintenance SectionBucket Linkage - Inspect/Adjust


7. Apply lubricant through tting (14) on the stickcylinder rod. Apply lubricant through tting (15).Fitting (15) is at the connection point of the boom

and of the stick. Apply lubricant through tting (16)on the bucket cylinder head end.

Grease Block on the Stick


(13) Left side connection point of boom and stick(14) Stick cylinder rod(15) Right side connection point of boom and stick(16) Bucket cylinder head end

Some machines may be equipped with a greaseblock that is located on the stick. Apply lubricantthrough the ttings.

i03933249

Bucket Linkage -Inspect/Adju stSMCS Code: 6513-025; 6513-040

Unexpected machine movement can cause injuryor death.

To avoid possible machine movement, move thehydraulic lockout control to the locked positionand attach a Special Instruction, SEHS7332, DoNot Operate or similar warning tag to the hy-draulic lockout control.

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


(1) N o gap(2) S tick boss(3) B ucket clearance(4) Shims(5) Plate(6) P in(7) Plate(8) Bolts

(9) Washers(10 ) Bolts(11) Washers(1 2) Location(1 3) Flange(1 4) Bucket boss

The clearance of the bucket control linkage onthis machine can be adjusted by shimming. If thegap between the bucket and the stick becomesexcessive, adjust bucket clearance (3) to 0.5 to 1 mm(0.02 to 0.04 inch).


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Bucket Tips - Inspect/Replace

Two shims of dif ferent thickness are used at location(12). The thicknesses of the shims are 0.5 mm(0.02 inch) and 1.0 mm (0.04 inch).


Area for linkage adjustmen t

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

2. Slowly operate the swing control lever until stickboss (2) and the bucket boss (14) are in full facecontact at no gap (1). This will help to determinethe total clearance of the connection point of thestick and of the bucket.

3. Move the hydraulic lockout control to the LOCKEDposition. Stop the engine.

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

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

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

6. Remove the appropriate number of shims atlocation (12) in order to meet the above thickness.Make sure that you use a minimum of three0.5 mm (0.02 inch) shims. To remove the shims,remove bolts (8), washers (9), plate (7), bolts (10),washers (11), and plate (5).

7. After the correct number of shims has beenremoved and pin (6) is aligned with the pin hole,install plate (5), washers (11), bolts (10), plate (7),washers (9), and bolts (8). Tighten the bolts to atorque of 240 40 Nm (175 30 lb ft).

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

i03574841

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

Personal injury or death can result from the bucketfalling.

Block the bucket before changing bucket tips.

Note: In order to maximize the life of the bucket tipand the penetration of the bucket tip, the bucket tipcan be rotated.


(1) Usable

(2) Replace(3) Overworn

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

Removal


Note: Retainers are often damaged during theremoval process. Caterpillar recommends theinstallation of a new retainer when bucket tips arerotated or replaced.


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264 SEBU8301-02Maintenance SectionBucket Tips - Inspect/Replace


1. Use a pry bar in order to disengage retainer (5).

2. Use the pry bar in order to remove retainer (5)

from bucket tip (4).

3. Remove bucket tip (4) from adapter (6) with aslight counterclockwise rotation.

4. Clean adapter (6).

Installation

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

2. Install the new bucket tip onto the adapter with aslight clockwise rotation.


3. Install the retainer. Make sure that the retainer'slatch catches under the tip pocket.

4. Make sure that the latch is properly seated bytrying to remove the bucket tip.

Side Cutters (If Equipped)


Bucket with side cutters

Side cutt ers

1. Remove the mounting bolts and the side cutters.

2. Clean the mounting surface of the side plate onthe bucket and of the side cutter. Remove anyburrs or protrusions on the mating surfaces.


(7) Side cutter

Note: Some side cutters may be rotated for additionalwear.

3. Install the side cutter.

Note: Certain bolts may require thread compound.

4. Hand tighten the bolts.


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Bucket Tips - Inspect/Replace


Section A-A From Illustration 291

(8) Side cutter (9) Shear ledge on a side cutter (10) Side plate on a bucket

(11) 0.0 mm (0.0 inch)

5. Make sure that there is not a gap between theside plate on the bucket and the shear ledge onthe side cutter.

6. Torque the mounting bolts to the correctspeci cation.

Side Protectors (If Equipped)

Inspect the wear of the side protector. When toomuch wear is present, replace the protector.




(12) Side protector (13) Pin(14) Retainer (15) Side plate(16) Shim

1. Hit pin (13) from the side of the bucket withoutthe retainer in order to remove side protector (12)from side plate (15).

2. Clean side protector (12), pin (13), retainer (14)and side plate (15) before installation.

Note: Lateral clearance between the side plateand the side protector should not exceed 1 mm(0.04 inch). Shims (16) may be required in order todecrease the lateral clearance which will decreasemovement. Install the shims(16) between the sideplate and the side protector on the opposite side of the retainer.

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

4. Align two pin holes of the new protector and theside plate. Hit the pin from the retainer side of thebucket.

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


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266 SEBU8301-02Maintenance SectionCab Air Filter (Fresh Air) - Clean/Replace

i01547055

Cab Air Filter (Fresh Air) -Clean/Replac eSMCS Code: 7342-070; 7342-510

g00730030Illustra tion 296

(1) Bolt(2) Filter cover

The cab air lter is behind the cab.

1. Loosen b olt (1) and open lter cover (2).


(2) Filter cover (3) Air lter

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

3. Clean the air lter with a maximum of 200 kPa(30 psi) pressure air.

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

5. Install the air lter and the lter cover.

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

i03173073

Camera - Clean/AdjustSMCS Code: 7348

Failure to use an appropriate external ladder or anappropriate platform for direct access to the rear view camera could result in slipping and fallingwhich could result in personal injury or death. Besure to use an appropriate external ladder or anappropria te platform for direct access to the rear view camera.

The machin e's counterweight and the enginehood are not approved as a maintenance plat-forms.

Unexpected machine movement can cause injuryor death.

In order to avoid possible machine move-ment, move the hydraulic lockout control to theLOCKED position and attach a Special Instruc-tion, SEHS7332, Do Not Operate or similar warning tag to the hydraulic lockout control.

When maintenance or servicing of the rear view

camera is required follow these steps.

1. Park the machine on a level surface.

2. Place the work tool on the level surface.

3. Move the hydraulic lockout control to the Lockedposition.

4. Turn the engine start switch to the OFF positionand remove the engine start switch key.

5. Turn the battery disconnect switch to theOFFposition and remove the battery disconnect switch

key.

Clean Camera Lens

If necessary, clean the camera lens before youoperate the machine. Use a soft cloth for cleaning.

Adjust the Area of Visibility

If the camera displays an undesired view, adjust thearea of the visibility.


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Camera - Clean/Adjust


(1) Cover (2) Bolt


(3) Bolt

1. Remove the 2 bolts (2) in order to remove thecover (1).

2. Unfasten the 2 bolts (3).


3. Adjust the area of the visibility of the camera sothat a 1.5 m (5 ft 11 inch) tall obstacle which is 1 m(3 ft) behind the counterweight can be seen.

4. Tighten the 2 bolts (3) to a torque of 0.5 0.05 Nm(4 0.4 lb in).

5. Tighten the 2 bolts (2) to a torque of 55 10 Nm(40 7 lb ft) in order to x the cover (1).

Work Area Vision System (If Equipped)

In order to maintain suf cient vision, keep the Work Area Vision System (WAVS) camera lens and thedisplay clean.

Display


WAVS display


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268 SEBU8301-02Maintenance SectionCircuit Breakers - Reset

Use a soft, damp cloth in order to clean the display.The display has a soft plastic surface that can beeasily damaged by an abrasive material. The displayis not sealed. Do not immerse the display withliquid.

Camera


Use a damp cloth or water spray in order to cleanthe came ra lens. The camera is a sealed unit. Thecamera is not affected by high pressure spray.

The came ra is equipped with an internal heater tohelp counteract the effects of condensation, snow,or ice.

Note: For more information on WAVS, refer toOperation and Maintenance Manual, SEBU8157,Work Area Vision System.

i02173231

Circuit Breakers - ResetSMCS Code: 1420-529


The circuit breaker is located behind the front left access door.

Main Circuit This circuit breaker isdesigned to protect the wires between thebatteries and the fuses. If the wires are

shorted to the machine's body, this circuit breaker would minimize the damage to the wires.

The main circ uit breaker has a capacity of 80 Amp.

Circuit Breaker Reset Push in the button in order to reset the circuit breaker. If the electrical system isworking properly, the button will remain depressed.If the button does not remain depressed, check theappropriat e electrical circuit. Repair the electricalcircuit, if necessary.

i02269887

Condenser (Refrigerant) -CleanSMCS Code: 1805-070

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

Repair the ns if found defective.

1. Open the middle access panel on the left side of the machine.


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

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

4. Close the access door.


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Cooling System Coolant (ELC) - Change

i03133221

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

NOTICEMixing Exte nded Life Coolant (ELC) with other prod-ucts reduces the effectiveness of the coolant andshortens coolant life. Use only Caterpillar prod-ucts or comm ercial products that have passed theCaterpillar EC-1 speci cations for premixed or con-centrate coolants. Use only Caterpillar Extender withCaterpill ar ELC. Failure to follow these recommenda-tions could result in the damage to cooling systemscomponents.

If ELC cooling system contamination occurs, refer to

Special Publication, SEBU6250, Cat Extended LifeCoolant ( ELC).

This machine was factory lled with Extended LifeCoolant .

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

Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and suppliessuitable to collect and contain uids on Caterpillar products.

Dispose of all uids according to local regulations andmandates.


1. Open the access cover for the cooling systempressure cap. The access cover for the coolingsystem pressure cap is located on top of themachine above the left rear access panel.

2. Slowly loosen the cooling system pressure cap

in order to re lease pressure. Remove the coolingsystem pressure cap.

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

3. Open the drain valve that is on the bottom of theradiator. The drain valve can be reached throughthe small a ccess hole that is located next to thedrain hose on the underside of the machine. Allowthe coolant to drain into a suitable container.

Note: Dispose of drained uids according to localregulations.

4. Flush the cooling system with clean water until thedraining water is clean.

5. Close the drain valve.

6. Add the E xtended Life Coolant. See Operationand Maintenance Manual, Capacities (Re ll).

7. Start th e engine. Operate the engine withoutthe cooling system pressure cap until the water temperature regulator opens and the coolant levelstabil izes.

8. Maintain the coolant level within 13 mm (0.5 inch)of the bottom of the ller pipe.

9. Check the gasket of the cooling system pressurecap. I f the gasket is damaged, replace thepressure cap.

10. Inst all the cooling system pressure cap and closethe access cover for the cooling system pressurecap.

11. Stop the engine.

12. Ope n the small storage compartment thatis located on the oor in front of the enginecompartment.


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270 SEBU8301-02Maintenance SectionCooling System Coolant Extender (ELC) - Add


Coolant reservoir

(1) FULL(2) LOW

13. Check the coolant reservoir. Maintain the coolantlevel between the FULL mark (1) and the LOWmark (2).

14. If additional coolant is necessary, remove thereservoir cap on top of the coolant reservoir andadd the appropriate coolant solution.

15. Install the reservoir cap.

16. Close the small storage compartment.

17. Close the left rear access panel and install thebolts for the left rear access panel.

i02192049

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

When a Caterpillar Extended Life Coolant (ELC) isused, an Extender must be added to the coolingsystem. See Special Publication, SEBU6250,Cooling Recommendations for all cooling systemrequirements.

Use a coolant conditioner test kit in order to checkthe concentration of the coolant.

NOTICEMixing Extend ed Life Coolant (ELC) with other prod-ucts reduces the effectiveness of the coolant andshortens coolant life. Use only Caterpillar prod-ucts or commer cial products that have passed theCaterpillar EC-1 speci cations for premixed or con-centrate coolants. Use only Caterpillar Extender withCaterpillar ELC. Failure to follow these recommenda-tions could result in the damage to cooling systemscomponents.

If ELC cooling system contamination occurs, refer toSpecial Publication, SEBU6250, Cat Extended LifeCoolant (EL C).

This machine was factory lled with Extended LifeCoolant.


1. Open the access cover for the cooling systempressure cap.

2. Slowly loosen the cooling system pressure capin order to release system pressure. Remove thepres sure cap.

Note: Refer to Operation and Maintenance Manual,Gen eral Hazard Information for information oncontaining uid spillage.

3. It may be necessary to drain some coolant from

the radiator so that Caterpillar Extender can beadded to the cooling system.

Note: Always discard drained uids according tolocal regulations.

4. Add Extender to the cooling system. Refer tothe following topics for the proper amount of Ca terpillar Extender:

Special Publication, SEBU6250, Cat ExtendedLife Coolant (ELC)


17/59


Cooling System Coolant Level - Check

Operation and M aintenance Manual, Capacities(Re ll)

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

6. Install the cooling system pressure cap.

7. Close the ac cess door for the cooling systempressure cap.

i02208390

Cooling Sy stem Coolant Level- CheckSMCS Code : 1350-040; 1350-535-FLV;

1395-535-FLV

1. Open the small storage compartment thatis located on the oor in front of the enginecompartment.


Coolant reservoir

(1) FULL(2) LOW

2. Che ck the coolant level of the coolant reservoir.Maintain the coolant level between the FULLmark and the LOW mark. If the coolant reservoir is empty, follow Steps 2.a through 2.i.


a. Open the access cover for the cooling systempressure cap.

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

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

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

Operation and Maintenance Manual,SEBU6250, Cooling System Speci cations

Operation and Maintenance Manual,Capacities (Re ll)

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

e. Maintain the coolant level within 13 mm(0.5 inch) of the bottom of the ller pipe.



18/59

272 SEBU8301-02Maintenance SectionCooling System Coolant Sample (Level 1) - Obtain

f. Inspect the con dition of the gasket on thepressure cap. If the gasket is damaged, replacethe pressure cap.

g. Install the cooling system pressure cap.

h. Stop the engi ne.

i. Close the access cover for the cooling systempressure ca p.

Note: Refer to Operation and Maintenance Manual,General Ha zard Information for information oncontaining uid spillage.

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

4. Install the reservoir cap.

5. Close the left access door.

i03134107

Cooling System CoolantSample (Level 1) - ObtainSMCS Cod e: 1395-008; 1395-554; 7542

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

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

Comm ercial long life coolants that meet theCaterpillar Engine Coolant Speci cation -1(Caterpillar EC-1)

Cat Diesel Engine Antifreeze/Coolant (DEAC)

Com mercial heavy-duty coolant/antifreeze

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

Note: Level 1 re sults may indicate a need for Level 2 Analysis.


Coolant sample port

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

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

Use the following guidelines for proper sampling of the coolant:

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

Keep the unused sampling bottles stored in plasticbags.

Obtain coolant samples directly from the coolantsample port. You should not obtain the samplesfrom any other location.

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

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

Never collect samples from expansion bottles.

Never collect samples from the drain for a system.

Submit the sample for Level 1 analysis.


19/59


Cooling System Coolant Sample (Level 2) - Obtain

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

i02049802

Cooling Syst em CoolantSample (Level 2) - ObtainSMCS Code: 1395-008; 1395-554; 7542

Reference: Refer to Operation and MaintenanceManual, Co oling System Coolant Sample (Level 1)- Obtain for the guidelines for proper sampling of the coolant.

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. Supplies

for colle cting samples can be obtained from your Caterpillar dealer.

Submit th e sample for Level 2 analysis.

Reference: For additional information about coolantanalysi s, refer to Special Publication, SEBU6250,Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer.

i03591653

Counterweight Removal Chain

- Clean(If Equipped)SMCS Code: 7056-070-CX

Proper operation of the Counterweight RemovalSystem depends on a properly lubricated counter-weight chain. If the chain is not lubricated prop-erly, the chain may rust and seize during the re-moval operation. A seized chain can fracture andresult in complete failure of the chain. The coun-terweight can then suddenly fall which can resultin personal injury or death.

Use an approved ladder or platform when lubricat-ing the upper portion of the chain.

If seizure of the chain occurs during counter-weight removal, stop the operation of the counter-weight removal system and contact your nearestdealer for chain replacement.

The counterwei ght removal chain must be clean andfree from rust. A chain with dirt or rust cannot bewound correctly.

1. If necessary, remove the entire chain assembly inorder to properly clean the chain assembly of rust

and foreign c ontaminants.

2. Clean the chain assembly with a clean,non ammabl e solvent and a wire brush.

3. Allow the chain assembly to dry. Lubricate thecounterwei ght removal chain. Refer to Operationand Maintenance Manual, CounterweightRemoval Chain - Lubricate for the proper procedure .

4. If the chain assembly was removed, install thechain asse mbly.

Note: Always clean the chain of rust and foreigncontamin ants.

i03481843

Counter weight Removal Chain- Inspect(If Equipped)SMCS Code: 7056-040-CX

Proper operation of the Counterweight RemovalSystem depends on a properly lubricated counter-weigh t chain. If the chain is not lubricated prop-erly, the chain may rust and seize during the re-moval operation. A seized chain can fracture andresu lt in complete failure of the chain. The coun-terweight can then suddenly fall which can resultin personal injury or death.


If seizure of the chain occurs during counter-weight removal, stop the operation of the counter-wei ght removal system and contact your nearestdealer for chain replacement.

Th e counterweight removal chain must be clean andfree from rust. A chain with dirt or rust cannot bewound correctly.

1. Inspect the chain.

2. Make sure that the chain is properly lubricated.


20/59

274 SEBU8301-02Maintenance SectionCounterweight Removal Chain - Lubricate

3. Make sure that t he chain is free of defects, rust,or foreign contaminants.

i03591620

Counterweight Removal Chain- Lubricate(If Equipped)SMCS Code: 7056-086-CX

Proper operation of the Counterweight RemovalSystem depends on a properly lubricated counter-weight chain. If the chain is not lubricated prop-erly, the chain may rust and seize during the re-moval operation. A seized chain can fracture and

result in complete failure of the chain. The coun-terweight can then suddenly fall which can resultin personal injury or death.


If seizure of the chain occurs during counter-weight removal, stop the operation of the counter-weight removal system and contact your nearestdealer for chain replacement.

The counterweight removal chain must be clean and

free from rust. A chain with dirt or rust cannot bewound correctly.

1. Inspect the chain.

2. Remove any foreign material and rust from thechain.


(1) Link plate edge. (2) Roller.

3. Lubricate the surfaces between each link plateedge (1) and roller (2) with SAE 30 engine oil.

Note: Always lu bricate the chain during removal of the counterweight, after the counterweight is loweredto the blocks on the ground.

i02270041

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

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


2. Loosen the two cover clamps and remove the air cleaner cover.


3. Remove the primary lter element from the air cleaner housing.

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

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


21/59


Engine Air Filter Primary Element - Clean/Replace

6. Inspect the pri mary lter. If the primary lter element is not damaged, you can clean theprimary element.

Refer to Cleaning Primary Air Filter Elements.


7. Direct air along the pleats inside the primary lter element and outside the primary lter element.

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

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

10. Install the clean primary lter.

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

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

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

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

Note: The primary lter can be cleaned up to sixtimes. Replace the primary lter if the primary lter has been used for one year.

Cleaning Primary Air Filter Elements

NOTICECaterpillar recommends certi ed air lter cleaning ser-

vices available at participating Caterpillar dealers. TheCaterpillar cleaning process uses proven proceduresto assure consistent quality and suf cient lter life.

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

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

Do not wash the lter element.

Use low pressure compressed air in order to removethe dust from the lter element. Air pressure must not

exceed 207 kPa (30 psi). Direct the air ow up thepleats and down the pleats from the inside of the lter element. Take extreme care in order to avoid damageto the pleats.

Do not use air lters with damaged pleats, gaskets, or seals. Dirt entering the engine will cause damage toengine components.

The primary air lter element can be used up to sixtimes if the element is properly cleaned and if theelement is properly inspected. When the primaryair lter element is cleaned, check for rips or tearsin the lter material. The primary air lter elementshould be replaced at least one time per year. Thisreplacement should be performed regardless of thenumber of cleanings.

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

Visually inspect the primary air lter elements before

cleaning. Inspect the air

lter elements for damageto the seal, the gaskets, and the outer cover. Discardany damaged air lter elements.

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

Pressurized air

Vacuum cleaning


22/59

276 SEBU8301-02Maintenance SectionEngine Air Filter Primary Element - Clean/Replace

Pressurized Ai r

Pressurized air can be used to clean primary air lter elements that have not been cleaned more than twotimes. Pressurized air will not remove deposits of carbon and oil. Use ltered, dry air with a maximum

pressure of 2 07 kPa (30 psi).


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

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

Vacuum Cleaning

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

Inspecting the Primary Air Filter Elements


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

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

Storing Primary Air Filter Elements

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



23/59


Engine Air Filter Secondary Element - Replace

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

Place the pri mary air lter element into a box for storage. For identi cation, mark the outside of thebox and mark the primary air lter element. Includethe followi ng information:

Date of cleaning

Number of cleanings

Store the b ox in a dry location.

i02270189

Engine Air Filter SecondaryElement - ReplaceSMCS Code: 1054-510

NOTICE Always replace the secondary lter element. Never at-tempt to reuse the secondary lter element by clean-ing the element.

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

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

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

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


3. Remove the secondary lter element.

4. Cover the air inlet opening. Clean the inside of

the air cleaner housing.

5. Remove the cover from the air inlet opening.

6. Install the new secondary lter element.

7. Install the primary lter element.

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


i01100443

Engine Air Precleaner - CleanSMCS Code: 1055-070-DJ

Check the engine air precleaner for accumulation of trash and dirt.


1. Loosen the latch and remove the cover from theprecleaner.

2. Clean the cover.


24/59

278 SEBU8301-02Maintenance SectionEngine Crankcase Breather - Clean

3. Clean the precl eaner. The precleaner can becleaned with pressure air, pressure water or adetergent. When pressure water is used, themaximum press ure should not exceed 280 kPa(40 psi).

Refer to Oper ation and Maintenance Manual,General Hazard Information before you usepressure air in order to clean the precleaner.

Note: Do not clean the precleaner by bumping or tapping the precleaner.

i02236028

Engine Crankcase Breather -CleanSMCS Code: 1317-070-DJ

NOTICEPerform this maintenance with the engine stopped.

If the crankcase breather is not maintained on aregular basis, the crankcase breather will becomeplugged. A plugged crankcase breather will causeexcessive crankcase pressure that may causecrankshaft seal leakage.

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


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

2. Loosen the hose clamp (2). Disconnect the outlethose (1) from the breather (4).

3. Loosen the clamp for the breather (3). Removethe breather and the seal.


4. Wash the breath er in a clean, non ammablesolvent.

5. Inspect the se al. If the seal is damaged, install anew seal.

6. Install the O -ring seal and the clean breather.Tighten the clamp for the breather.

7. Slide the ho se onto the breather. Tighten the hoseclamp.

8. Close the en gine hood. Latch the engine hood.

i02207916

Engine Oil Level - CheckSMCS Code: 1000-535

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

Note: This machine's monitoring system checks uidlevels. However, if the machine is on an incline or theengine has been stopped only for a short time, theengine oil does not return to the crankcase. The uidlevel cannot be properly checked. Park the machineon level ground and check the oil level after the

engine has been stopped for at least 30 minutes.The oil level can be checked while the engine isrunning. The oil level can also be checked while theengine is stopped. The recommended procedure ischecking the oil while the engine is stopped.

1. Unlatch the engine hood and raise the enginehood.


(1) Dipstick for the engine oil(2) Filler plug for the engine oil


25/59


Engine Oil Sample - Obtain

2. Remove dipstic k (1). Wipe the oil off the dipstickand reinsert the dipstick.


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

level is between the ADD and FULL marks onthe ENG INE STOPPED side of the dipstick.

4. If the oil level is too low go to Step 5. Otherwise,proceed to Step 8.

Note: Refer to Operation and Maintenance Manual,Gener al Hazard Information for information thatpertains to containing uid spillage.

5. Unscre w oil ller plug (2) and remove the oil ller plug.

Note: Oil that is badly contaminated or deterioratedshould be replaced early regardless of the changeinterval.

NOTICEOper ating your engine when the oil level is above theFULL mark could cause your crankshaft to dip intothe oil. The air bubbles created from the crankshaftdipp ing into the oil reduces the oil's lubricating char-acteristics and could result in the loss of power.

6. Add oil until the oil level is between the ADD andFULL marks on the ENGINE STOPPED sideof the dipstick.

7. Clean the ller plug and install the ller plug.

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

i02207897

Engine Oil Sample - ObtainSMCS Code: 1000-008; 1000; 1348-008;

1348-554-SM; 7542-008; 7542-554-OC, SM


Obtain a sample of the engine oil from theengine o il sampling valve that is located in theengine compartment. Refer to Special Publication,SEBU6250, SOS Oil Analysis for information thatpertain s to obtaining a sample of the engine oil.Refer to Special Publication, PEHP6001, How ToTake A Good Oil Sample for more information aboutobtain ing a sample of the engine oil.

i02349623

Engine Oil and Filter - ChangeSMCS Code: 1318-510

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

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

Note: Drain the crankcase while the oil is warm. Thisallows waste particles that are suspended in the oil todrain. As the oil cools, the waste particles will settleto the bottom of the crankcase. The particles will notbe removed by draining the oil and the particles willrecirculate in the engine lubrication system with thenew oil.


26/59

280 SEBU8301-02Maintenance SectionEngine Oil and Filter - Change


The drain hose for the engine crankcase is located under the rear of the upper structure.

1. Remove the bolts and the washers for the

crankcase drain valve access cover. Remove theaccess cover.



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



4. Op en the access door to the engine compartment.


(1) Dipstick(2) Filter (3) Filler plug

5. Remove the oil

lter (2) with a strap type wrench.Note: Dispose of the used oil lter according to localregulations.

6. Inspect the oil lter. See Operation andMaintenance Manual, Oil Filter - Inspect.

7. Clean the lter housing base. Make sure that all of the old lter gasket is removed.


8. Apply a thin coat of engine oil to the gasket of

the new lter.Note: There are rotation index marks on each engineoil lter that are spaced 90 degrees or 1/4 of a turnaw ay from each other. When you tighten engine oil lters, use the rotation index marks as a guide.

9. Install the engine oil lter hand tight until the sealof the engine oil lter contacts the base. Note theposition of the index marks on the lter in relationto a xed point on the lter base.


27/59


Engine Valve Lash and Fuel Injector Timing - Check

10. Tighten the lter according to the instructions thatare printed on the lter. Use the index marks asa guide.

11. Unscrew the oil ller plug (3) and remove the oil ller plug.

12. Fill the crankcase with new oil. See Operationand Maintenance Manual, Capacities (Re ll).

13. Clean the oil ller plug and install the oil ller plug.

NOTICEDo not unde r ll or over ll engine crankcase with oil.Either condition can cause engine damage.

NOTICEOperating your engine when the oil level is above theFULL mark could cause your crankshaft to dip intothe oil. The air bubbles created from the crankshaftdipping into the oil reduces the oil's lubricating char-acteristics and could result in the loss of power.

14. Start the engine and allow the oil to warm. Checkthe engine for leaks. Stop the engine.

15. Wait for 30 minutes so that the oil can drain backinto the crankcase, before you check the oil.

16. Remove the dipstick (1). Wipe the oil off thedipstick and reinsert the dipstick.


17. Remove the dipstick again. Make sure that the oillevel is between the ADD and FULL marks onthe ENGINE STOPPED side of the dipstick.

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

19. Install the crankcase drain valve access cover with the bolts and the washers.

i00707053

Engine Valve Lash and FuelInjector Timi ng - CheckSMCS Code: 1105-025; 1209-535; 1290-531-FT

Refer to the Service Manual for the completeprocedure for checking the engine valve lash. Thisprocedure l ists the steps for the engine valve lashadjustment and the steps in order to check the enginevalve lash.

Note: Make sure that a quali ed mechanic works onthe injector fuel timing. Special tools and training arerequired.

Refer to the Service Manual for the completeprocedure for checking the injector fuel timing or for adjusting the injector fuel timing.

Note: The correct fuel timing speci cation isgiven on the Engine Information Plate. Fueltiming speci cations may differ for distinct engineapplica tions and/or power ratings.

i00059702

Engine Valve Rotators - InspectSMCS Code: 1109-040

When inspecting the valve rotators, protectiveglasses or face shield and protective clothingmust be worn to prevent being burned by hot oilspray.

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


2. Watch the top surface on each valve rotator. Eachvalve rotator should turn slightly whenever thecylinder valve closes.


28/59

282 SEBU8301-02Maintenance SectionEther Starting Aid Cylinder - Replace

If a cylinder va lve fails to rotate, consult your Caterpillar dealer.

i02203372

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

Refer to Op eration and Maintenance, Fire Preventionand Explosion Prevention before you replace theether cylinders.

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


(1) Retaining clamps(2) Ether cylinder

2. Loosen the cylinder retaining clamps (1). Unscrewthe empty ether cylinder (2) and remove the emptyether cylinder.

3. Remove the used seal. Install the new seal. Anew seal is provided with each new ether startingaid cylinder.

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

5. Close the access door and install the two bolts.

i03908954

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

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

g00822278Illustr ation 332

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

1. Position one nal drive so that oil drain plug (2) isat the bottom.

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

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

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. Inst all drain plug (2).

5. Fill the nal drive to the bottom of the opening on

lev el plug (1). See Operation and MaintenanceManual, Lubricant Viscosities and Operation andMaintenance Manual, Capacities (Re ll) .

Note: If the oil lls slowly, the ll hole may be blockedby the planetary gear. Rotate the nal drive in order to move the planetary gear away from the ll hole.

Note: Over lling the nal drive will cause the sealson the travel motor to allow hydraulic oil or water to enter the nal drive. The nal drive may becomecontaminated.

6. Install level plug (1).


29/59


Final Drive Oil Level - Check

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

8. Completely remove the oil that has spilled ontosurfaces.

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

10. Stop the engine. Check the oil level.

11. Check the dr ained oil for metal chips or for particles. If there are any chips or particles, consultyour Caterpillar dealer.

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

i03914051

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

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



1. Position one nal drive so that oil drain plug (2) isat the bottom.

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

2. Remove oil level plug (1).

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

4. Add oil through the level plug opening, if necessary. See Operation and Maintenance,Lubricant Viscosities.

Note: If the oil lls slowly, the ll hole may be blockedby the planetary gear. Rotate the nal drive in order

to move the pl anetary gear away from the ll hole.

Note: Over lling the nal drive will cause the sealson the trave l motor to allow hydraulic oil or water to enter the nal drive. The nal drive may becomecontaminated.

5. Clean oil level plug (1). Inspect the O-ring seal.Replace the O-ring seal if the O-ring seal is wornor damaged .

6. Install oil level plug (1).

7. Repeat the procedure for the other nal drive.

i03756611

Final Dr ive Oil Sample - ObtainSMCS Code: 4011-008; 4050-008; 4050-SM;

7542-00 8




1. Po sition the nal drive so that oil drain plug (2) isat the bottom.


2. Remove oil level plug (1).


30/59

284 SEBU8301-02Maintenance SectionFuel System - Prime

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

4. Install oil le vel plug (1).

Refer to Special Publication, SEBU6250, Caterpillar

Machine Flui ds Recommendations, SOS Oil Analysis for more information on obtaining a sampleof the nal drive oil. For additional information abouttaking an oi l sample, refer to Special Publication,PEGJ0047, How To Take A Good Oil Sample.

i02249787

Fuel Syste m - PrimeSMCS Code: 1250-548

1. Open the engine access doors.


(1) Vent plug(2) Priming pump plunger

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

3. Turn priming pump plunger (2) counterclockwisein order to unlock priming pump plunger (2).Operate priming pump plunger (2).

4. Tighten vent plug (1) when the fuel ows withoutair bubbles.

5. Push in priming pump plunger (2) and tightenpriming pump plunger (2) by hand.

6. Crank the engine. If the engine does not start or if the engine mis res, additional priming is required. Also if the engine emits smoke, additional primingis required.

7. If the engine starts but the engine runs rough,continue to run the engine at low idle. Run theengine at low idle until the engine runs properly.

8. Check the fuel system for leaks. Stop the engine.

9. Close the engin e access doors.

i03901456

Fuel System Primary Filter

(Water Separator) Element -ReplaceSMCS Code: 1263-510-FQ

Personal i njury or death may result from failure toadhere to the following procedures.

Fuel leak ed or spilled onto hot surfaces or electri-cal components can cause a re.

Clean up a ll leaked or spilled fuel. Do not smokewhile working on the fuel system.

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

NOTICEDo not ll the fuel lters with fuel before installing thefuel lters. The fuel will not be ltered and could becontaminated. Contaminated fuel will cause acceler-ated wear to fuel system parts.

The primary lter/water separator is located behindthe access door on the right side of the machine.

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


(1) Shutoff valve(2) Bowl(3) Filter (4) Drain valve

2. Turn off the fuel supply to the fuel lter by turningshutoff valve (1) clockwise.


31/59


Fuel System Secondary Filter - Replace

3. Turn drain valv e (4) counterclockwise in order toopen. The drain valve is located on the bottomof the water separator.

Note: Refer to Operation and Maintenance Manual,General Hazard Information for information that

pertains to c ontaining uid spillage.

4. Drain the water and the sediment into a suitablecontainer.

Note: Dispose of used uids according to localregulation s.

5. Close drain valve (4).

6. Remove lter (3) from the lter base. A lter wrench may be used to loosen the lter.

7. Remove lter (3) from bowl (2). Discard the used lter.

Note: The water separator bowl is reusable. Do notdiscard the water separator bowl.

8. Clean the inside surfaces of lter base and bowl(2).


(2) Bowl(3) Filter (5) Cap(6) Seal

9. Remove cap (5) from the bottom of new lter (3).Remove seal (6) from cap (5) and inspect theseal for damage. Replace the seal if the seal isdamaged.

10. Lubricate the seal (6) for the bowl (2) with cleandiesel fuel or lubricate the seal with clean motor oil. Place the seal in the groove in the bowl.

11. Install the bowl (2) onto the new lter by handuntil the bowl is snug. Tighten the bowl to 10 Nm(7 lb ft) to approximately 1/6 of a turn. Do not usetools to tighten the bowl to the new lter.

12. Lubricate the s eal on the new lter with cleandiesel fuel or lubricate the seal with clean motor oil.

13. Install the new lter by hand.

Instruction s for the installation of the lter areprinted on the side of each Caterpillar spin-on lter. For non-Caterpillar lters, refer to theinstallati on instructions that are provided by thesupplier of the lter.

Note: Do not start the engine until all service tothe fuel system is complete. For instructions aboutpriming the fuel system, refer to Operation andMaintenan ce Manual, Fuel System - Prime.


i02249791

Fuel System Secondary Filter -ReplaceSMCS Code: 1261-510

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

Do not ll fuel lters with fuel before installing them.Contaminated fuel will cause accelerated wear to fuelsystem parts.

1. Open the engine access doors.


2. Remove the fuel lter.

3. Inspect the fuel lter for debris by cutting the fuel lters open.

Note: The fuel lters are cartridge type lters. The lters cannot be reused.


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286 SEBU8301-02Maintenance SectionFuel System Water Separator - Drain

Note: Dispose o f used lters and used uidsaccording to local regulations.

4. Clean the lte r mounting base. Make sure that allof the old seal is removed.


5. Lubricate the seal of the new lter with cleandiesel fuel.

6. Install the new lter by hand. Additionally tightenthe lter by 3/4 of a turn, after the gasket contactsthe lter base.

Every new lter has four rotation index marks.Each mark indicates 1/4 turn. Use these rotationindex marks as a guide for proper tightening.

7. Prime the fuel system. Refer to Operation and

Maintenance, Fuel System - Prime.

8. Close the engine access doors.

i022 49789

Fuel System Water Separator - Dra inSMCS Code: 1263

1. Open the front access door on the right side of the machine. The lter is located to the right of

the steps.


2. If water is present, drain the water from the bowl.

3. Turn the drain valve counterclockwise in order to

open.


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




i01589598

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


1. Remove the fuel cap.


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Fuel Tank Water and Sediment - Drain

2. Inspect seal (4 ) for damage. Replace the seal, if necessary.

3. Remove screws (1), lter assembly (2), drainvalve (3) and the gaskets.



4. Remove the strainer that is located in the ller opening.

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

6. Install a new cap lter kit. Install the gaskets, drainvalve (3), lter assembly (2), and screws (1).

7. Install the strainer into the ller opening.

8. Install the fuel tank cap.

i02203465

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

The fuel tank drain valve is located on the side of themachine under the fuel tank.



1. Open the drain valve by turning the valvecounterclockwise. Allow the water and thesediment to drain into a suitable container.


2. Close the drain valve by turning the valveclockwise.

Fill the Fuel Tank

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

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

i030 95213

Fuses - ReplaceSMCS Code: 1417-510

Ope n the access door on the left side of the machine.

The fuse panel is located on the circuit breaker panel.Ope n the access cover for fuse access.

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

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


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288 SEBU8301-02Maintenance SectionFuses - Replace

NOTICE Always replac e fuses with the same type and capacityfuse that was removed. Otherwise, electrical damagecould result.

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

Contact your Caterpillar dealer.

To replace a fuse, use the puller that is stored in thefuse panel. The following spare fuses are stored inthe fuse panel: one fuse of 5 Amperes, two fuses of 10 Amperes, two fuses of 15 Amperes, and one fuseof 30 Amperes.

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


(1) Spare 5 Amp

(2) Spare 10 Amp

(3) Spare 10 Am p

(4) Spare 15 Amp

(5) Spare 15 Amp

(6) Spare 30 Amp

(7) Radio Converter 10 Amp

(8) Air Conditioner 1 10 Amp

(9) Cab Ligh t 10 Amp

(10) Horn 10 Amp

(11) Spare 10 Amp

(12) Machi ne Control Module 1 15 Amp

(13) Product Link 5 Amp

(14) Engine Start Switch 10 Amp

(15) Auxi liary Control 15 Amp

(16) Cab Dome Light and Radio Memory 15 Amp

(17) Heater and Air Conditioner Blower Fan 15 Amp

(18) Electric Refueling Pump 30 Amp

(19) Wi ndow Wiper and Window Washer 15 Amp

(20) Chassis Light 10 Amp

(21) Seat Heater 10 Amp

(22) C igar Lighter 10 Amp

(23) Radio 15 Amp

(24) Automatic Lubrication 10 Amp

(25) 12 Volt 7 Amp Converter 10 Amp

(26) 12 Volt 7 Amp Converter 10 Amp

(27) Air Conditioner 2 15 Amp

(28 ) Auxiliary 1 10 Amp

(29) Auxiliary 2 10 Amp

(30) Auxiliary 3 10 Amp

(31) Attachment Solenoid and Travel Alarm 10 Amp

(32) Engine Control Module (ECM) 15 Amp


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High Intensity Discharge Lamp (HID) - Replace

(33) Boom's Lef t Light 10 Amp

(34) Boom's Right Light 10 Amp

(35) Beacon 10 Amp

(36) Air Susp ension Seat and Camera 10 Amp

(37) Radio Converter 5 Amp

(38) SmartBoom 5 Amp


(39) Chassis Lamp Relay

(40) Cab Lamp Relay

(41) Horn Relay

(42 ) Travel Alarm Relay

(43) Neutral Start Relay

(44) Ether Relay

(45) Boom Light 1 Relay

(46) Boom Light 2 Relay

i02245859

High Intensity Discharge Lamp(HID) - Replac e(If Equipped)SMCS Code: 14 34-510

HID lamps op erate at very high voltages. To avoidelectrical shock and personal injury, disconnectpower before servicing HID lamps.

HID bulbs become very hot during operation.Before servicing, remove power from lamp for atleast ve minutes to ensure lamp is cool.

NOTICE Although HID bulb materials may change over time,HID bulbs produced at the time of the printing of thismanual c ontain mercury. When disposing of this com-ponent, or any waste that contains mercury, pleaseuse caution and comply with any applicable laws.

1. Remove the electrical power from the highintensity discharge lamp (HID). The electricalpower m ust be removed from the HID lamp for

at least ve minutes, in order to ensure that thebulb is cool.

2. Disassemble the housing for the HID lamp in order to have access to the bulb.

Note: On some HID lamps, the bulb is an integralpart of the lens assembly. The bulb is not removedsepa rately from the lens assembly. Replace theentire lens assembly on these HID lamps.

3. Rem ove the bulb from the HID lamp.

4. Install the replacement bulb in the HID lamp.

If the bulb is an integral part of the lens assembly,install the replacement lens assembly in the HIDlamp.

Note: In order to avoid failure to the bulb that ispr emature, avoid touching the bulb's surface withyour bare hands. Clean any ngerprints from the bulbwith alcohol prior to operation.

5. Reassemble the housing for the HID lamp. Ensurethat any printing on the lens is oriented correctlywith respect to the HID lamp's mounting positionon the machine.


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290 SEBU8301-02Maintenance SectionHydraulic System Filter Element (Fine Filtration) - Replace

6. Reattach the el ectrical power to the HID lamp.

7. Check the HID lamp for proper operation.

Note: Consult your Caterpillar dealer for additionalinformation on HID lamps.

i03974449

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

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

1. Place the machine in the servicing position.

2. Move th e hydraulic lockout control to the LOCKEDposition. Stop the engine.


3. Slowly loosen the ller plug in order to relieve anypressure.

4. Tighten the ller plug after the pressure is relieved.

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


6. Remove four bolts (1) and cover (2) from the ne ltration lter.

7. Remove element (3) from the lter assembly.

8. Install a new lter element.

9. Install cover (2) and four bolts (1).


i03450960

Hydraulic System Oil - ChangeSMCS Code: 5056-044

Cat HYDO Advanced 10 Oil ChangeInterval

The standard Cat HYDO Advanced 10 oil changeinterval is every 3000 service hours or 18 months.

A maintenance interval of 6000 service hours or 3years for changing the hydraulic oil is available. Theextended interval requires SOS monitoring of thehydraulic oil. The interval for SOS monitoring isevery 500 hours. The maintenance interval for thehydraulic oil lter is not changed.

Machines with hammers are not included in themaintenance interval of 6000 service hours or 3 years. Machines with hammers must use the intervalsthat are listed in the Maintenance Interval Schedule.Machines that are used in severe conditions are notincluded in the maintenance interval of 6000 servicehours or 3 years. Machines that are used in severeconditions must use the interval in the MaintenanceInterval Schedule.


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Hydraulic System Oil - Change

Drain the Oil


1. Park the machine in the servicing position on levelground.

2. Clean the top of the hydraulic tank thoroughly inorder to keep dirt out of the hydraulic tank.


3. Relieve the internal pressure from the hydraulictank b y loosening the ll/vent plug. After thepressure is relieved, remove the ll/vent plug.


4. Remove the two access covers that are locatedunder the hydraulic tank. This will allow access tothe drain valve and the pipe.



5. Remove plug (1).


(2) Drain plug(3) Pipe Nipple(4) Tube

6. Install a pipe nipple (3) with a clear plastic tube (4)into the hole on the bottom of the hydraulic tank.

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

8. Drain the oil into a suitable container.

9. After the oil has been drained, tighten drain plug(7) to a torque of 110 15 Nm (81 11 lb ft).

10. Remove the pipe nipple.

11. Clean plug (1) and install the plug. Tighten theplug to a torque of 75 5 Nm (55 48 lb ft).


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292 SEBU8301-02Maintenance SectionHydraulic System Oil - Change


12. Remove the plug from the tube. Allow the oil todrain into a container.

13. Inspect the O-ring. Replace the O-ring if wear or damage is evident.

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


15. Remove the cover to the hydraulic tank screen.


(5) Spring(6) Screen

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

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

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

17. Wash the screen in a clean non ammable solvent. Allow the screen to dry. Inspect the screen.Replace the screen, if the screen is damaged.

18. There is an O-ring seal on the bottom of thescreen. There is also an O-ring seal on thehydraulic tank around the opening for the screen.Inspect the O-ring seals. Replace the O-ring sealsif wear or damage is evident.

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

Note: Make sure that the O-ring seals and the spring

are properly positioned during installation.

Service the Hydraulic SystemFilters

Note: The hydraulic oil system must be empty whenthe lters are being serviced. Service the ltersbefore re lling the machine with hydraulic oil.

Note: Dispose of used lters and used uidsaccording to local regulations.


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Hydraulic System Oil Filter (Case Drain) - Replace

Refer to the fol lowing topics in order to service thehydraulic system lters:

Operation and Maintenance Manual, HydraulicSystem Filter Element (Fine Filtration) - Replace(If Equipped)

Operation and Maintenance Manual, HydraulicSystem Oil Filter (Return) - Replace

Operation and Maintenance Manual, HydraulicSystem Oil Filter (Case Drain) - Replace

Operation and Maintenance Manual, HydraulicSystem Oil Filter (Pilot) - Replace

Fill the Hydraulic Tank

1. Fill the hydraulic system oil tank. Refer to

Operation and Maintenance Manual, Capacities(Re ll).

2. Inspect the O-ring seal on the ller plug for damage. R eplace the O-ring, if necessary. Cleanthe ller plug. Install the ller plug.

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

When the hydraulic oil has been replaced, the air must be removed from the hydraulic oil system.To remo ve the air from the hydraulic oil system,

follow Step 2.a through Step 2.d.a. Start the engine.


b. Slowly loosen the vent plug on top of the casedrain lter until hydraulic oil ows out of thevent plug.

c. After oil ows o ut of the vent plug withoutany air bubbles, tighten the vent plug. Thisindicates that the air has been purged from thedrain lines fo r the main pump and the drain linefor the swing pump. Tighten the vent plug to atorque of 11 1 Nm (97 9 lb in).

d. Stop the engine.

3. Start the en gine. Operate the engine at idlingspeed for ve minutes.

4. Operate the joysticks in order to circulate thehydraulic oil. Return the machine to the servicingposition. Stop the engine.


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

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

i022 70478

Hydraulic System Oil Filter (Cas e Drain) - ReplaceSMCS Code: 5068-510; 5091-510

1. Open the right front access door.

2. Cle an the area in order to keep dirt out of the lter base.


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294 SEBU8301-02Maintenance SectionHydraulic System Oil Filter (Case Drain) - Replace


3. Slowly loosen vent plug (1) that is on top of the lter in order to release the pressure from the lter.Tighten the vent plug.

4. Remove the used case drain lter (2) from the lter base.

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

Note: Dispose of used lters according to localregulations.

5. Clean the lter base.


6. Coat the seal of a new case drain lter with cleanhyd raulic oil. Install the new case drain lter in the lter base. Tighten the case drain lter hand tight.

7. Af ter replacing any hydraulic lter, the air mustbe purged from each lter. Perform Step 7.athrough Step 7.c in order to purge the air from thehy draulic system.

a. Start the engine.

b. Slowly loosen the vent plug on top of the lter until oil ows out of the vent plug.

c. Tighten the ven t plug.

8. Drive the machine slowly for 10 to 15 minutes.Move each cyli nder evenly through several cycles.

9. Return the machine to the servicing position.

Check the mac hine for oil leaks.

10. Stop the engine.


(A) High temperature range(B) L

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