MAINTENANCE INTERVALS

Operation and Maintenance

Manual Excerpt

® ®
© 2010 Caterpillar
All Rights Reserved
 SEBU6933-04
November 1999

Operation and
Maintenance
Manual
M312 and M315 Excavators
6TL1-Up (Machine)
7ML1-Up (Machine)
 143
Maintenance Section
Maintenance Interval Schedule

i01197903 Every 50 Service Hours or Weekly

Maintenance Interval Schedule Boom, Stick and Bucket Linkage - Lubricate ...... 150
Boom, Stick and Bucket Linkage - Lubricate ...... 150
SMCS Code: 7000 Drive Shaft Universal Joint - Lubricate ............... 167
Tire Inflation - Check ........................................... 203
Note: All safety information, warnings, and Wheel Nut Torque - Check .................................. 207
instructions must be read and understood before
you perform any operation or any maintenance Every 100 Service Hours or 2 Weeks
procedure.
Axle Oscillation Bearings - Lubricate .................. 148
Before each consecutive interval is performed, all Blade Linkage - Lubricate ................................... 149
of the maintenance requirements from the previous Stabilizer Bearings - Lubricate ............................ 201
interval must also be performed.
Every 250 Service Hours or Monthly
When Required
Air Conditioner - Test .......................................... 145
Battery - Recycle ................................................ 148 Axle Bearings (Front) - Lubricate ........................ 146
Battery, Battery Cable or Battery Disconnect Switch - Axle Oil Level (Front) - Check ............................. 147
Replace ............................................................. 149 Axle Oil Level (Rear) - Check ............................. 148
Bucket Tips - Inspect/Replace ............................ 153 Braking System - Test ......................................... 152
Cab Air Filter - Clean/Replace ............................ 155 Condenser (Refrigerant) - Clean ........................ 155
Drum Brakes - Inspect ........................................ 168 Cooling System Hoses - Inspect ......................... 163
Engine Air Filter Primary Element - Engine Oil and Filter - Change ........................... 176
Clean/Replace .................................................. 168 Final Drive Oil Level - Check ............................... 179
Engine Air Filter Secondary Element - Replace .. 170 Swing Bearing - Lubricate .................................. 201
Fuel System Priming Pump Strainer - Clean ...... 181 Transmission Oil Level - Check ........................... 204
Fuses - Replace .................................................. 186 V-Belts - Inspect/Adjust/Replace ........................ 205
Oil Filter - Inspect ................................................ 198
Refueling Pump Strainer - Clean ........................ 200 Initial 500 Service Hours
Windows - Clean ................................................. 207
Window Washer Reservoir - Fill .......................... 208 Axle Oil (Front) - Change .................................... 146
Window Wiper - Inspect/Replace ........................ 208 Axle Oil (Rear) - Change .................................... 147
Final Drive Oil - Change ..................................... 178
Every 10 Service Hours or Daily for First 100 Transmission Oil - Change .................................. 203
Hours
Every 500 Service Hours or 3 Months
Boom, Stick and Bucket Linkage - Lubricate ...... 150
Drive Shaft Support Bearing Lubricant - Check .. 167
Boom, Stick and Bucket Linkage - Lubricate ...... 150
Fuel System Primary Filter/Water Separator Element
- Replace ........................................................... 179
Every 10 Service Hours or Daily Fuel System Priming Pump - Operate ................ 180
Boom, Stick and Bucket Linkage - Lubricate ...... 150 Fuel System Secondary Filter - Replace ............ 182
Brakes, Indicators and Gauges - Test ................. 151 Fuel Tank Cap and Strainer - Clean ................... 184
Cooling System Level - Check ............................ 165
Engine Oil Level - Check .................................... 175 Every 1000 Service Hours or 6 Months
Fuel System Water Separator - Drain ................. 183
Fuel Tank Water and Sediment - Drain ............... 185 Axle Oil (Front) - Change .................................... 146
Axle Oil (Rear) - Change .................................... 147
Hydraulic System Oil Level - Check .................... 196
Battery Hold-Down - Tighten .............................. 149
Hydraulic System Oil Level - Check .................... 197
Radiator Core - Clean ......................................... 199 Drum Brakes - Inspect ........................................ 168
Final Drive Oil - Change ..................................... 178
Seat Belt - Inspect .............................................. 201
Overhead Guard - Inspect .................................. 199
Travel Alarm - Test .............................................. 204
Walk-Around Inspection ...................................... 206 Transmission Oil - Change .................................. 203

Every 10 Service Hours or Daily for Machines Every 2000 Service Hours or 1 Year
Used in Severe Applications Cooling System Water Temperature Regulator -
Replace ............................................................. 166
Boom, Stick and Bucket Linkage - Lubricate ...... 150
Engine Crankcase Breather Filter - Replace ...... 171
Engine Crankcase Breather Filter - Replace ...... 173
Engine Valve Lash and Fuel Injector Timing -
Check ................................................................ 178
144
Maintenance Section
Maintenance Interval Schedule

Hydraulic System Oil - Change ........................... 189

Hydraulic System Oil - Change ........................... 191
Hydraulic System Oil Filter - Clean ..................... 193
Hydraulic System Oil Filter - Replace ................. 193
Hydraulic System Oil Filter - Replace ................. 194
Hydraulic System Oil Filter - Replace ................. 194
Hydraulic System Oil Filter - Replace ................. 195
Hydraulic System Oil Filter - Replace ................. 196
Swing Gear - Lubricate ....................................... 202

Every 3 Years
Seat Belt - Replace ............................................. 201

Every 3000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .. 160
Cooling System Coolant Extender (ELC) - Add .. 161

Every 4000 Service Hours or 2 Years

Engine Crankcase Breather Valve - Replace ...... 174

Every 6000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 156
Cooling System Coolant (ELC) - Change ........... 158
 145
Maintenance Section
Air Conditioner - Test

i00679706

Air Conditioner - Test

(If Equipped)
SMCS Code: 7320-081

Inhaling air conditioner refrigerant gas through a

lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air con-
ditioner refrigerant gas can cause bodily harm or
death. Do not smoke when servicing air condition-
g00101966
ers or wherever refrigerant gas may be present. Illustration 255

4. Look at the sight glass on the receiver-dryer and

note the amount of refrigerant.

Bodily injury can occur from unexpected contact

with open cab doors on machines equipped with
a fixed cab riser.

To avoid injury, close the cab door before climbing

onto the rear of the machine.

g00101967
Illustration 256

• Sight glass (A) contains only a few bubbles. This

indicates that there is a satisfactory amount of
refrigerant.

• In sight glass (B), many bubbles are present. This

Illustration 254 g00290119 indicates that there is a lack of refrigerant.
(1) Access door. (2) Top access cover.
• In sight glass (C), small amounts of vapor are
present. This indicates that there is almost no
1. Open access door (1) on the left side of the
refrigerant.
machine. Secure the access door.
If the condition in sight glass (B) or in sight glass
2. Open access cover (2).
(C) is noticed, consult your authorized Caterpillar
dealer for recharging.
3. Start the engine. Turn the engine speed dial to
the medium speed position.
Operation of the air conditioner without correct
amounts of refrigerant could cause failure of the
compressor.

The air conditioner should be kept ready for

operation year-round. Operate the air conditioner
for a few minutes during the week in order to
rotate the compressor. This prevents the leakage of
refrigerant. The leakage is caused by a dry seal
on the compressor.
146
Maintenance Section
Axle Bearings (Front) - Lubricate

i00060139

Axle Bearings (Front) -

Lubricate
SMCS Code: 3278-086

The front axle is the axle which steers the machine.

The rear axle is the one with the gearbox.

Wipe all grease fittings before you apply grease.

g00242127
Illustration 258
(1) Filler Plug. (2) Drain Plug.

1. Remove the dirt that is around filler plug (1) and

around drain plug (2).

Note: Refer to Operation and Maintenance Manual,

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

2. Remove drain plug (2). Allow the lubricant to

Illustration 257
g00102403 drain into a suitable container.

The fittings are behind the front tires. Note: Dispose of drained fluids according to local
regulations.
A grease fitting is positioned on the top of the
steering axle. Another grease fitting is positioned 3. Clean drain plug (2).
on the bottom of the steering axle. Apply grease to
these fittings at each end of the steering axle. 4. Inspect the O-ring seal. If damage or wear is
found, replace the O-ring seal.
For access to the U-joints, fully turn the wheels
to the left or to the right. The machine wheels 5. Install drain plug (2).
may require rotation in order to access the grease
fittings. 6. Remove filler plug (1).

7. Add lubricant through the filler plug opening.

i00310408 Maintain the lubricant level to the bottom of
the filler plug opening. Refer to Operation and
Axle Oil (Front) - Change Maintenance Manual, “Refill Capacities”.
SMCS Code: 3278-044 8. Clean filler plug (1).
The front axle is the axle which steers the machine. 9. Inspect the O-ring seal. If damage or wear is
The rear axle is the one with the gearbox. noticed on the O-ring seal, replace the seal.

10. Install filler plug (1).

 147
Maintenance Section
Axle Oil (Rear) - Change

i01011566 4. Inspect the O-ring seal. If damage or wear is

noticed on the O-ring seal, replace the seal.
Axle Oil (Rear) - Change
5. Install drain plug (2).
SMCS Code: 3278-044
6. Remove filler plug (1).

7. Fill the axle with lubricant to the bottom of

the filler plug opening. See Operation and
Maintenance Manual, “Refill Capacities”.

8. Clean filler plug (1).

9. Inspect the O-ring seal. If damage or wear is

noticed on the O-ring seal, replace the seal.

10. Install filler plug (1).

i00312048
g00102672
Illustration 259
(1) Filler plug Axle Oil Level (Front) - Check
SMCS Code: 3278-535

The front axle is the axle which steers the machine.

The rear axle is the one with the gearbox.

g00333762
Illustration 260
(2) Drain plug

Operate the machine for an adequate amount of

time in order to warm the lubricant. g00102631
Illustration 261
Filler plug (1) and drain plug (2) are located under
the machine on the rear axle. 1. Remove the dirt that is around the filler plug.

Note: Refer to the Operation and Maintenance 2. Remove the filler plug.
Manual, “General Hazard Information” for
information in containing fluid spillage. 3. Maintain the lubricant level to the bottom of the
filler plug opening. Add lubricant through the
1. Remove the dirt that is around filler plug (1) and filler plug opening, as needed.
around drain plug (2).
4. Clean the filler plug.
2. Remove drain plug (2). Drain the lubricant into a
suitable container. 5. Inspect the O-ring seal. If damage or wear is
noticed on the O-ring seal, replace the seal.
Note: Dispose of any used lubricant according to
local regulations. 6. Install the filler plug.

3. Clean drain plug (2).

148
Maintenance Section
Axle Oil Level (Rear) - Check

i00703208

Axle Oil Level (Rear) - Check

SMCS Code: 3278-535

The front axle is the axle which steers the machine.

The rear axle is the one with the gearbox.

g00102404
Illustration 263

A steer axle pin is positioned at the front of the

machine. A grease fitting is positioned on the front
of the steer axle pin. Apply grease to this grease
fitting.

g00102672
Illustration 262
(1) Filler plug

1. Remove the dirt that is around the filler plug (1).

2. Remove filler plug (1).

3. Maintain the lubricant level to the bottom of the

filler plug opening. Add lubricant through the
filler plug opening, as needed.

4. Clean filler plug (1).

g00102405
5. Inspect the O-ring seal. If damage or wear is Illustration 264
noticed on the O-ring seal, replace the seal.
A grease fitting is also positioned on the rear of the
6. Install filler plug (1). steer axle pin. Apply grease to this grease fitting.

i00060143 i00059329

Axle Oscillation Bearings - Battery - Recycle

Lubricate SMCS Code: 1401-561
SMCS Code: 3268-086-BD; 3268; 3278-086-BD; Always recycle a battery. Never discard a battery.
3278; 3282; 4313
Always return used batteries to one of the following
Wipe all the grease fittings before you apply grease. locations:

• A battery supplier
• An authorized battery collection facility
• Recycling facility
 149
Maintenance Section
Battery Hold-Down - Tighten

i00934872 i01048535

Battery Hold-Down - Tighten Blade Linkage - Lubricate

SMCS Code: 7257
(If Equipped)
SMCS Code: 6060-086-KL
Tighten the hold-downs for the battery in order to
prevent the batteries from moving during machine
operation. Note: Caterpillar recommends the use of 5P-0960
Molybdenum Grease for lubricating the boom,
stick and bucket linkage. Refer to Operation and
i00663586 Maintenance Manual, SEBU6250, “Lubricating
Grease” for more information on the Molybdenum
Battery, Battery Cable or Grease.
Battery Disconnect Switch - Wipe all fittings before lubricating.
Replace
SMCS Code: 1401-510; 1402-510; 1402-510

1. Turn the engine start switch to the OFF position.

Turn all switches to the OFF position.

2. Turn the battery disconnect switch to the OFF

position. Remove the disconnect switch key.

3. Remove the secondary steering fuse.

4. Disconnect the battery cable at the battery

disconnect switch. The battery disconnect switch
is connected to the machine frame.
g00103933
Illustration 265
Note: Do not allow the disconnected battery cable
to contact the battery disconnect switch. 1. Raise the access cover.

5. 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 batteries.

6. Make all of the necessary repairs or replace the

battery.

7. Connect the negative battery cable at the battery.

8. Connect the negative battery cable at the battery

that is connected to the battery disconnect
switch. g00103934
Illustration 266
9. Install the secondary steering fuse.

10. Connect the battery cable at the battery

disconnect switch.

11. Install the disconnect switch key and turn the

battery disconnect switch to the ON position.
150
Maintenance Section
Boom, Stick and Bucket Linkage - Lubricate

2. Apply lubricant through fittings (1), (2) and (3).

i01047178

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, SEBU6250, “Lubricating
g00103935
Grease” for more information on Molybdenum
Illustration 267 Grease.
2. Apply lubricant through the six fittings that are 1. Wipe all fittings before you apply lubricant.
shown in Illustrations 266 and 267 on each side
of the blade. There are a total of 12 fittings.

3. Close the access cover.

i01047177

Boom, Stick and Bucket

Linkage - Lubricate
(Ditch Cleaning Bucket (If
Equipped))
SMCS Code: 6501-086; 6502-086; 6513-086
g00102387
Illustration 269
Note: Caterpillar recommends the use of 5P-0960
Molybdenum Grease for lubricating the boom, 2. Apply lubricant through the front grease fitting
stick and bucket linkage. Refer to Operation and that is by the head end of the right boom cylinder.
Maintenance Manual, SEBU6250, “Lubricating
Grease” for more information on the Molybdenum Note: This fitting supplies grease to all linkage
Grease. bearings from the frame to the nose of the boom.
The valve is designed to give the proper amount of
1. Wipe all fittings before you apply lubricant. grease to all bearings. If the valve will not accept
grease, one of the lines is blocked.

Use Steps 2.a through 2.d to ensure proper

lubrication.

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.
g00354074
Illustration 268 d. Apply grease through the grease fitting.
(1) Fittings
(2) Fittings
(3) Fitting
 151
Maintenance Section
Brakes, Indicators and Gauges - Test

i00664174

Brakes, Indicators and Gauges

- Test
SMCS Code: 4251-081; 4267-081; 4269-081;
7450-081; 7490-081

g00105234
Illustration 270
(1) Fitting
(2) Fittings
(3) Fitting

3. Apply lubricant through fittings (1), (2), and (3).

Note: Fitting (2) is located on each side of the stick. g00291446

Illustration 272

1. Look for broken lenses and for broken indicator

lights.

2. Start the engine.

3. Look for inoperative gauges.

4. Turn on all machine lights. Check for proper

operation.

5. Sound the horn.

6. Move the machine forward. Release the travel

Illustration 271 g00105235 pedal. Depress the service brake pedal. The
machine should stop.
(4) Fitting
(5) Fittings
(6) Fittings 7. Stop the engine.
(7) Fitting
8. Before you operate the machine, make all
4. Apply lubricant through fittings (4), (5), (6), and necessary repairs.
(7).
152
Maintenance Section
Braking System - Test

i00767599

Braking System - Test

SMCS Code: 3077-081; 4011-081; 4250-081;
4251-081; 4267-081

Service Brake Holding Ability Test

Personal injury can result from a sudden stop dur-

ing brake test.
g00102514
Make sure the area is clear of personnel and ob- Illustration 273
structions before testing the brakes. Fasten the (1) Service brake pedal
seat belt before moving the machine. (2) Travel speed pedal

1. Start the engine. Keep the engine speed at low

If the machine begins to move during the test, idle.
engage the parking brake immediately.
2. Slightly raise all implements.
Make sure that the area around the machine is clear
of personnel and of obstacles. 3. Depress service brake pedal (1).
Test the service brakes on a dry, level surface.

Fasten the seat belt before you test the brakes.

The following test determines if the service brakes

are functional. This test is not intended to measure
the maximum brake holding effort. The maximum
brake holding effort that is required to hold a
machine stationary at a certain engine rpm varies
between machines. These differences are caused
by differences in the following factors:

• Engine setting
• Power train efficiency Illustration 274
g00291447

(3) Parking brake switch

• Brake holding ability (4) Transmission control

• Other factors 4. Release the parking brake by using parking

brake switch (3).

5. Place transmission control (4) in the FIRST GEAR

position.

6. Without releasing the service brake pedal,

depress the front of travel speed pedal (2) to
the FORWARD position. The machine should not
move. Release the travel speed pedal.

7. Engage parking brake (3). This is the end of the

test of the service brakes.

8. Lower all the implements to the ground. Apply a

slight downward pressure to the control lever.

9. Stop the engine.

 153
Maintenance Section
Bucket Tips - Inspect/Replace

i01117817
NOTICE
If the machine moved while testing the service brakes,
Bucket Tips - Inspect/Replace
contact your Caterpillar dealer.
SMCS Code: 6805-040; 6805-510
Have the dealer inspect and, if necessary, repair the
service brakes before returning the machine to oper-
ation.
Personal injury or death can result from bucket
falling.
Testing the Brake Accumulator
Block the bucket before changing bucket tips or
1. Move the engine start switch key to the ON side cutters.
position.

Bucket Tips

g00291450
Illustration 275

2. The low brake pressure indicator should come Illustration 276

g00101352
on if the accumulator is not at normal operating
(1) Usable
pressure. (2) Replace this bucket tip.
(3) Overworn
3. Start the engine.
Check the bucket tips for wear. If the bucket tip has
4. Run the engine for two minutes in order to a hole, replace the bucket tip.
increase the accumulator pressure. The low
brake pressure indicator should turn off. 1. Remove the pin from the bucket tip. The pin can
be removed by one of the following methods.
5. Stop the engine.
• Use a hammer and a punch from the retainer
6. While the engine is stopped, turn the engine side of the bucket to drive out the pin.
start switch to the ON position. Apply the service
brakes five times. If the low brake pressure • Use a Pin-Master. Follow Step 1.a through Step
indicator comes on within five applications of the 1.c for the procedure.
service brakes, consult your Caterpillar dealer.
154
Maintenance Section
Bucket Tips - Inspect/Replace

g00590670 g00101359
Illustration 277 Illustration 279
(4) Back of Pin-Master
(5) Extractor 4. Install the new bucket tip onto the adapter.

a. Place the Pin-Master on the bucket tooth. Note: The bucket tip can be rotated by 180
degrees in order to allow greater penetration or less
b. Align extractor (5) with the pin. penetration.

c. Strike the Pin-Master at the back of the tool 5. Drive the pin through the bucket tip. The pin
(4) and remove the pin. can be installed by using one of the following
methods:

• From the other side of the retainer, drive the

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

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

5.e for the procedure.

g00590819
Illustration 278
(6) Retainer
(7) Retaining washer
(8) Adapter

2. Clean the adapter and the pin.

3. Fit retainer (6) into retaining washer (7). Install

this assembly into the groove that is in the side Illustration 280
g00590666
of adapter (8). (4) Back of Pin-Master
(9) Pin setter
(10) Pin holder

a. Insert the pin through the bucket tooth.

b. Place the Pin-Master over the bucket tooth

and locate the pin in the hole of holder (10).

c. Strike the tool with a hammer at the back of

the tool (4) in order to start the pin.
 155
Maintenance Section
Cab Air Filter - Clean/Replace

d. Slide pin holder (10) away from the pin and

rotate the tool slightly in order to align pin
setter (9) with the pin.

e. Strike the end of the tool until the pin is fully

inserted.

6. After you drive the pin, make sure that the

retainer fits snugly into the pin groove.

Side Cutters

g00102283
Illustration 283
(1) Screws
(2) Cover for the Cab Air Filter

1. Remove two screws (1) and cover (2).

2. Remove the filters.

3. Clean the filters with pressure air or wash the

filters in a solution of warm water and nonsudsing
household detergent.
g00114738
Illustration 281
4. Rinse the filters in clean water. Thoroughly air
dry the filters.
1. Remove the mounting bolts and the side cutters.
5. Install the filters.
2. Clean the mounting surfaces.
6. Install cover (2). Secure the cover with two
Note: Some side cutters may be rotated for
screws (1).
additional wear.
7. Replace the access cover to the cab riser
3. Install the new side cutters or the rotated side
compartment.
cutters.

i00662834
i00706051

Cab Air Filter - Clean/Replace Condenser (Refrigerant) -

Clean
SMCS Code: 7342-070; 7342-510
(If Equipped)
SMCS Code: 1805-070

Bodily injury can occur from unexpected contact

with open cab doors on machines equipped with
a fixed cab riser.

To avoid injury, close the cab door before climbing

onto the rear of the machine.

g00291487
Illustration 282
The cab air filters are under the cab.
156
Maintenance Section
Cooling System Coolant (ELC) - Change

i01047363
NOTICE
If excessively dirty, clean condenser with a brush. To
Cooling System Coolant (ELC)
prevent damage or bending of the fins, do not use a - Change
stiff brush.
SMCS Code: 1350-044
Repair the fins if found defective.
S/N: 6TL1-539
S/N: 6TL542-634
S/N: 7ML1-1060
S/N: 7ML1065-1214

NOTICE
Do not change the coolant until you read and under-
stand the material in the Operation and Maintenance
Manual, “Cooling System Specifications”.

NOTICE
Mixing Extended Life Coolant (ELC) with other
Illustration 284 g00290119 products reduces the effectiveness of the coolant
(1) Access door
and shortens coolant life. Use only Caterpillar prod-
(2) Access cover ucts or commercial products that have passed the
Caterpillar EC-1 specifications for premixed or con-
1. Open access door (1) that is on the left side of centrate coolants. Use only Caterpillar Extender with
the machine. Secure the access door. Caterpillar ELC. Failure to follow these recommenda-
tions could result in the damage to cooling systems
2. Open access cover (2). components.

If ELC cooling system contamination occurs, refer to

Operation and Maintenance Manual, “Extended Life
Coolant (ELC)” under the topic ELC Cooling System
Contamination.

This machine was filled with Extended Life Coolant

at the factory.

If the coolant is dirty or if you observe any foaming

in the cooling system, drain the coolant before the
recommended interval.

If the coolant in the machine is changed to Extended

g00101950
Life Coolant from another type of coolant, see
Illustration 285 Operation and Maintenance Manual, SEBU6250,
“Extended Life Coolant (ELC) Cooling System
3. Inspect the condenser for debris. Clean the Maintenance”.
condenser, if necessary.

4. Use clean water to wash off all dust and dirt

from the condenser.
Bodily injury can occur from unexpected contact
5. Close the access door and the access cover. with open cab doors on machines equipped with
a fixed cab riser.

To avoid injury, close the cab door before climbing

onto the rear of the machine.
 157
Maintenance Section
Cooling System Coolant (ELC) - Change

4. There is a cover under the radiator. Remove the

screws and the cover under the radiator in order
to expose the drain valve in Illustration 289.

g00289939
Illustration 286

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

machine. Secure the access door. Illustration 289 g00518357

Note: Refer to the Operation and Maintenance

Manual, “General Hazard Information” for
information in containing fluid spillage.

5. Open the drain valve. Allow the coolant to drain

into a suitable container.

Note: Dispose of drained fluids according to local

regulations.

6. Flush the cooling system with clean water until

the draining water is clean.

g00309306 7. Close the drain valve. Replace the cover under

Illustration 287
the radiator and secure the cover under the
radiator.

8. Add the Extended Life Coolant. Refer to the

following topics:

• Operation and Maintenance Manual,

SEBU6250, “Cooling System Specifications”

• Operation and Maintenance Manual, “Refill

Capacities”

9. Start the engine. Run the engine without the

pressure cap. Run the engine until the water
temperature regulator opens and the coolant
Illustration 288 g00518336 level stabilizes.

2. The radiator is at the top right of the machine.

The cooling system pressure cap is above the
radiator under the small access cover. Open the
access cover to the pressure cap. Slowly loosen
the pressure cap in order to relieve the pressure.
Remove the pressure cap.

3. Remove the radiator cap.

158
Maintenance Section
Cooling System Coolant (ELC) - Change

i01237637

Cooling System Coolant (ELC)

- Change
SMCS Code: 1350-044
S/N: 6TL540-541
S/N: 6TL635-Up
S/N: 7ML1061-1064
S/N: 7ML1215-Up

g00518359 NOTICE
Illustration 290
Do not change the coolant until you read and under-
10. Open the radiator access cover. Secure the stand the material in the Operation and Maintenance
access cover. Manual, “Cooling System Specifications”.

NOTICE
Mixing Extended Life Coolant (ELC) with other
products reduces the effectiveness of the coolant
and shortens coolant life. Use only Caterpillar prod-
ucts or commercial products that have passed the
Caterpillar EC-1 specifications for premixed or con-
centrate coolants. Use only Caterpillar Extender with
Caterpillar ELC. Failure to follow these recommenda-
tions could result in the damage to cooling systems
components.

If ELC cooling system contamination occurs, refer to

Operation and Maintenance Manual, “Extended Life
g00102899
Illustration 291 Coolant (ELC)” under the topic ELC Cooling System
Contamination.
11. Maintain the coolant level to the center of the
sight gauge. This machine was filled with Extended Life Coolant
at the factory.
12. Install the radiator cap.
If the coolant is dirty or if you observe any foaming
13. Stop the engine. in the cooling system, drain the coolant before the
recommended interval.
14. Close all access covers and the access door.
Secure all access covers and the access door. If the coolant in the machine is changed to Extended
Life Coolant from another type of coolant, see
Operation and Maintenance Manual, SEBU6250,
“Extended Life Coolant (ELC) Cooling System
Maintenance”.

Bodily injury can occur from unexpected contact

with open cab doors on machines equipped with
a fixed cab riser.

To avoid injury, close the cab door before climbing

onto the rear of the machine.
 159
Maintenance Section
Cooling System Coolant (ELC) - Change

g00289939 g00518357
Illustration 292 Illustration 294

1. Open the access door on the left side of the Note: Refer to the Operation and Maintenance
machine. Secure the access door. Manual, “General Hazard Information” for
information in containing fluid spillage.

5. Open the drain valve. Allow the coolant to drain

into a suitable container.

Note: Dispose of drained fluids according to local

regulations.

6. Flush the cooling system with clean water until

the draining water is clean.

7. Close the drain valve. Replace the cover under

the radiator and secure the cover under the
radiator.
g00518336
Illustration 293

2. The radiator is at the top right of the machine.

The cooling system pressure cap is above the
radiator under the small access cover. Open the
access cover to the pressure cap. Slowly loosen
the pressure cap in order to relieve the pressure.
Remove the pressure cap.

3. Remove the radiator cap.

4. There is a cover under the radiator. Remove the

screws and the cover under the radiator in order
to expose the drain valve in Illustration 294.
g00542482
Illustration 295

8. Remove the vent plug and the seal. Refer to

Illustration 295.

9. Add the Extended Life Coolant. Refer to the

following topics:

• Operation and Maintenance Manual,

SEBU6250, “Cooling System Specifications”

• Operation and Maintenance Manual, “Refill

Capacities”
160
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

10. Install the vent plug and the seal. Tighten the i01048541
vent plug to a torque of 9 ± 1 N·m (6.6 ± 0.7 lb ft).
Cooling System Coolant
Extender (ELC) - Add
SMCS Code: 1352; 1353; 1395
S/N: 6TL1-539
S/N: 6TL542-634
S/N: 7ML1-1060
S/N: 7ML1165-1214

Note: This machine was filled with Caterpillar

Extended Life Coolant at the factory.
g00518359
Illustration 296 When Caterpillar Extended Life Coolant (ELC)
is used, a Caterpillar ELC Extender must be
11. Open the radiator access cover. Secure the added to the cooling system. See the Operation
access cover. and Maintenance Manual, SEBU6250, “Coolant
Recommendations” for all cooling system
requirements.

Use an 8T-5296 Coolant Conditioner Test Kit to

check the concentration of the coolant.

NOTICE
Use only Caterpillar products or commercial products
that have passed Caterpillar EC-1 specification for
pre-mixed or concentrated coolants.

Use only Caterpillar Extender with Extended Life

Coolant.

Illustration 297
g00102899 Mixing Extended Life Coolant with other products re-
duces the Extended Life Coolant service life. Failure to
12. Add coolant until the coolant level is at the follow the recommendations can reduce cooling sys-
center of the sight gauge. tem components life unless appropriate corrective ac-
tion is performed.
13. Start the engine and run the engine without the
radiator cap. Run the engine until the coolant Note: Refer to Operation and Maintenance Manual,
level stabilizes. If necessary, add coolant in order SEBU6250, “Extended Life Coolant (ELC)” for
to maintain the coolant level at the center of the instructions regarding contamination of the ELC
sight gauge. Cooling System.
14. Stop the engine.

15. Install the radiator cap.

Bodily injury can occur from unexpected contact
16. Close all access covers and the access door. with open cab doors on machines equipped with
Secure all access covers and the access door. a fixed cab riser.

To avoid injury, close the cab door before climbing

onto the rear of the machine.
 161
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

3. You may be required to drain enough coolant

from the radiator in order to allow the addition of
the Caterpillar ELC Extender. If this is necessary,
refer to Operation and Maintenance Manual,
“Cooling System Coolant (ELC) - Change” for the
location of the radiator drain valve.

Note: Dispose of drained fluids according to local

regulations.

4. Add the proper amount of Caterpillar ELC

Extender to the cooling system. Refer to
Operation and Maintenance Manual, “Refill
Capacities” and Operation and Maintenance
g00289939 Manual, SEBU6250, “Extended Life Coolant
Illustration 298 (ELC)” for the proper quantity.
1. Open the access door on the left side of the 5. Replace the radiator cap if the gasket is
machine. Secure the access door. damaged. Install the radiator cap. Close the
cover over the radiator cap.

6. Close and secure the access door on the left

side of the machine.

i01237714

Cooling System Coolant

Extender (ELC) - Add
SMCS Code: 1352; 1353; 1395
S/N: 6TL540-541
g00309306 S/N: 6TL635-Up
Illustration 299

S/N: 7ML1061-1064
S/N: 7ML1215-Up

Note: This machine was filled with Caterpillar

Extended Life Coolant at the factory.

When Caterpillar Extended Life Coolant (ELC)

is used, a Caterpillar ELC Extender must be
added to the cooling system. See the Operation
and Maintenance Manual, SEBU6250, “Coolant
Recommendations” for all cooling system
requirements.

Illustration 300 g00518336 Use an 8T-5296 Coolant Conditioner Test Kit to

check the concentration of the coolant.
2. The radiator is at the top right of the machine.
Open the access cover for the radiator cap.
Slowly loosen the radiator cap in order to relieve
the pressure. Remove the radiator cap.
162
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

NOTICE
Use only Caterpillar products or commercial products
that have passed Caterpillar EC-1 specification for
pre-mixed or concentrated coolants.

Use only Caterpillar Extender with Extended Life

Coolant.

Mixing Extended Life Coolant with other products re-

duces the Extended Life Coolant service life. Failure to
follow the recommendations can reduce cooling sys-
tem components life unless appropriate corrective ac-
tion is performed.
g00518336
Illustration 302
Note: Refer to Operation and Maintenance Manual,
SEBU6250, “Extended Life Coolant (ELC)” for 2. The radiator is at the top right of the machine.
instructions regarding contamination of the ELC Open the access cover for the radiator cap.
Cooling System. Slowly loosen the radiator cap in order to relieve
the pressure. Remove the radiator cap.

3. You may be required to drain enough coolant

from the radiator in order to allow the addition of
Bodily injury can occur from unexpected contact the Caterpillar ELC Extender. If this is necessary,
with open cab doors on machines equipped with refer to Operation and Maintenance Manual,
a fixed cab riser. “Cooling System Coolant (ELC) - Change” for the
location of the radiator drain valve.
To avoid injury, close the cab door before climbing
onto the rear of the machine. Note: Dispose of drained fluids according to local
regulations.

4. Add the proper amount of Caterpillar ELC

Extender to the cooling system. Refer to
Operation and Maintenance Manual, “Refill
Capacities” and Operation and Maintenance
Manual, SEBU6250, “Extended Life Coolant
(ELC)” for the proper quantity.

g00289939
Illustration 301

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

machine. Secure the access door.

g00542482
Illustration 303

5. After the system has been filled with the extender,

loosen the air purge valve in order to release the
air from the system.

6. Replace the radiator cap if the gasket is

damaged. Install the radiator cap. Close the
cover over the radiator cap.
 163
Maintenance Section
Cooling System Hoses - Inspect

7. Close and secure the access door on the left

side of the machine.

i01010703

Cooling System Hoses -

Inspect
SMCS Code: 1380-040

Bodily injury can occur from unexpected contact

with open cab doors on machines equipped with Illustration 306
g00518425
a fixed cab riser.
3. Inspect all hoses for leaks due to cracking,
To avoid injury, close the cab door before climbing for softness next to the clamps, and for loose
onto the rear of the machine. clamps.

4. Replace hoses that are cracked or soft and

tighten any loose clamps.

Replace the Hoses

g00289939
Illustration 304

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

machine. Secure the access door.

g00309306
Illustration 307

1. The radiator is at the top right of the machine.

Open the access cover to the radiator cap.

g00518246
Illustration 305

2. Open the access cover that is on the top of the

machine.

g00518336
Illustration 308
164
Maintenance Section
Cooling System Hoses - Inspect

2. Slowly loosen the radiator cap in order to relieve

the system pressure. Remove the radiator cap.

3. The drain valve is under the radiator. Open the

access cover in order to gain access to the drain
valve.

g00518359
Illustration 310

10. Open the radiator access cover. Secure the

access cover.

g00518357
Illustration 309

Note: Refer to Operation and Maintenance Manual,

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

4. Open the drain valve. Allow the coolant to drain

into a suitable container.

Note: Dispose of drained fluids according to local

regulations.

5. Close the drain valve. g00102892

Illustration 311
6. Loosen the hose clamps and disconnect the
damaged hose. 11. Maintain the coolant level to the center of the
sight gauge.
7. Replace the damaged hose with a new hose.
12. Install the radiator cap.
8. Add the coolant solution. Refer to the Operation
and Maintenance Manual, “Refill Capacities”. 13. Stop the engine.

Note: If you are using Caterpillar Antifreeze, do not 14. Close and secure all of the access covers and
add a supplemental coolant additive. If you are not all of the access doors.
using Caterpillar Antifreeze, add a supplemental
coolant additive.

9. Start the engine. Run the engine without the

radiator cap. Run the engine until the water
temperature regulator opens and the coolant
level stabilizes.
 165
Maintenance Section
Cooling System Level - Check

i00995126 Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” on containing fluid
Cooling System Level - Check spillage.
SMCS Code: 1350-535 3. If additional coolant is needed, open the access
door on the left side of the machine. Secure the
access door.

Bodily injury can occur from unexpected contact

with open cab doors on machines equipped with
a fixed cab riser.

To avoid injury, close the cab door before climbing

onto the rear of the machine.

g00518359
Illustration 312

1. Open the radiator access cover. Secure the

radiator access cover.

g00309306
Illustration 315

g00102305
Illustration 313

2. Maintain the coolant level to the center of the

sight gauge.

g00518336
Illustration 316

4. The radiator cap is on the top right side of the

machine. Open the access cover to the radiator
cap. Slowly loosen the radiator cap in order to
relieve the system pressure.

If you must add coolant daily, check the coolant

system for leaks.
g00289939
Illustration 314 5. Remove the radiator cap.

6. Add the coolant.

166
Maintenance Section
Cooling System Water Temperature Regulator - Replace

7. Inspect the radiator cap and the gasket for the

following defects: NOTICE
Failure to replace the water temperature regulator on a
• Damage regularly scheduled basis could cause severe engine
damage.
• Deposits
Never operate an engine without the water tempera-
• Foreign material ture regulator installed.
Clean the radiator cap with a clean cloth or If the water temperature regulator is installed incor-
replace the radiator cap if the radiator cap is rectly, the engine may overheat, causing cylinder head
damaged. damage. Ensure that the new water temperature reg-
ulator is installed in the original position.
8. Install the radiator cap. Close the access cover
to the radiator cap.
Note: Always discard drained fluids according to
9. Close the access door on the left side of the local regulations.
machine.

10. Inspect the radiator core for debris. Clean the

radiator core, as needed. See Operation and
Maintenance Manual, “Radiator Core - Clean”.

11. Close the radiator access cover. Secure the

radiator access cover.

i00995133

Cooling System Water

Temperature Regulator -
Replace Illustration 317
g00317003

(1) Access door

SMCS Code: 1355-510 (2) Access cover

Note: Refer to the Service Manual, “Disassembly 1. Access door (1) is on the left side of the machine.
and Assembly” for detailed instructions regarding Open access door (1). Secure the access door.
the cooling system.

Replacing the water temperature regulator prior to

failure is a recommended preventive maintenance
practice. This replacement will reduce the chances Bodily injury can occur from unexpected contact
for cooling system problems and for unscheduled with open cab doors on machines equipped with
downtime. a fixed cab riser.

If one of the following conditions is met, the To avoid injury, close the cab door before climbing
replacement of the water temperature regulator can onto the rear of the machine.
be done:
2. Open access cover (2).
• The cooling system is drained and the cooling
system is cleaned.

• The cooling system is drained to a level that

is below the water temperature regulator
housing. This is the best option if only the water
temperature regulator is being replaced.
 167
Maintenance Section
Drive Shaft Support Bearing Lubricant - Check

i00687064

Drive Shaft Support Bearing

Lubricant - Check
(If Equipped)
SMCS Code: 3267-535

g00518433
Illustration 318

3. Loosen the hose clamp. Remove the hose from

the elbow.

4. Remove the bolts from the elbow. Remove the

elbow. Remove the gasket.
g00102456
5. Remove the water temperature regulator from the Illustration 319
water temperature regulator housing.
The drive shaft support bearings are located below
Note: Inspect the gasket before assembly. If wear the center of the machine.
or damage is found, replace the gasket.
1. Remove the plug.
6. Install a new water temperature regulator. Install
the gasket. Install the elbow. Install the bolts in 2. Check the lubricant level. The bearings should
the elbow. be covered with lubricant.

7. Connect the hose to the elbow. Tighten the hose Note: Refer to Operation and Maintenance Manual,
clamps. “General Hazard Information” for information in
Containing Fluid Spillage.
8. Restore the coolant level to the correct operating
level. Refer to the Operation and Maintenance 3. If necessary, add lubricant.
Manual, “Cooling System Level - Check” for
details.
i00995144

9. Close and secure access cover (2). Close and Drive Shaft Universal Joint -
secure access door (1).
Lubricate
SMCS Code: 3251-086; 3253-086

g00102443
Illustration 320
168
Maintenance Section
Drum Brakes - Inspect

The grease fittings are located below the center of

the machine.

Apply grease to the one fitting on the universal joint

at both ends of the drive shaft. Some machines are
equipped with two-piece drive shafts. The two-piece
drive shaft has two additional fittings.

i00995186

Drum Brakes - Inspect

(If Equipped)
SMCS Code: 4252-040 g00103931
Illustration 322
S/N: 7ML1-Up
4. Measure the thickness of the brake shoe pad. If
The brake shoe pads should be inspected more the thickness of the brake shoe pad is less than
frequently than every 1000 service hours or 6 2 mm (0.079 inch) at any point and the brake
months when the brake shoe pads are near shoe pads are assembled with glue, then replace
replacement. the brake shoes. For riveted brake shoe pads, if
the thickness of the brake shoe pad is less than
1. Remove the wheel on the rear axle. 1 mm (0.039 inch) at any point then replace the
brake shoes. Refer to the Service Manual for the
Note: Refer to Disassembly and Assembly Manual, replacement procedure of brake shoes.
SENR6258, “Remove & Install Tire & Rim Assemblies
(Rear)” for more information on removing the rear 5. Install the brake drums.
tire and installing the rear tire.
6. Install the tires.

i00994381

Engine Air Filter Primary

Element - Clean/Replace
SMCS Code: 1054-070; 1054-510

NOTICE
Never service the air cleaner with the engine running,
since this will allow dirt to enter the engine.

g00103930 Check the air duct for leaks. Make all repairs to leaky
Illustration 321
air ducts immediately, as dirt and debris could enter
the engine causing damage to the turbocharger and
2. Remove the brake drums. engine components.
3. Visually inspect the brake line for leaks. Repair
any leaks. Replace any parts that are worn or
damaged.
 169
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace

g00106825 g00309383
Illustration 323 Illustration 325

Service the air cleaner if the dash indicator light 2. Release three clamps (1). Remove cover (2).
comes on and the engine is running at high idle.
Stop the engine.

A primary element may be cleaned for a maximum

of six times. Also replace the primary element if the
primary element has been used for one year.

The secondary filter element should also be

replaced when any one of the following conditions
occurs:

• The primary filter element is serviced for the third

time.

• The dash indicator light comes on and the engine g00309423

is running at high idle after the primary filter Illustration 326
element has been serviced.
3. Remove the primary filter element from the air
• The exhaust smoke is black after the primary filter cleaner housing.
element has been serviced.
4. Clean the inside of the air cleaner housing.
See Operation and Maintenance Manual, “Engine
Air filter Secondary Element - Replace”. 5. Inspect the primary element. If the pleats, the
gaskets, or the seals are damaged, discard the
element. Replace a damaged primary element
with a clean primary element.

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 re-
maining in the elements can cause false indications of
contamination in Scheduled Oil Sampling test results.

g00290071
Illustration 324 6. If the primary element is not damaged, clean the
primary element.
1. In order to access the filter elements, open the
access cover on the right side of the machine. The filter elements can be cleaned by using the
following methods:
170
Maintenance Section
Engine Air Filter Secondary Element - Replace

• Pressure air i00726894

• Pressure water Engine Air Filter Secondary

Element - Replace
• Detergent washing
SMCS Code: 1054-510
If you use pressure air, use a maximum air
pressure of 205 kPa (30 psi). If you use pressure
NOTICE
water, use a maximum water pressure of 280 kPa
Always replace the secondary filter element. Never at-
(40 psi).
tempt to reuse the secondary filter element by clean-
ing the element.

When the primary filter element is cleaned for the third

time, 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.

1. Remove the primary filter element and the

cover. See the Operation and Maintenance
Manual, “Engine Air Filter Primary Element -
Clean/Replace”.
g00102012
Illustration 327

7. When you clean the inside pleats and the outside

pleats, direct the air or the water along the pleats.

The element can be washed in a solution that

consists of warm water and of nonsudsing
household detergent. Fully rinse the pleats. Allow
the filter to air dry completely.

8. Inspect the filter elements after you clean the

filter elements. Do not use a filter if the pleats,
the gaskets or the seals are damaged.

9. Cover the clean filter elements. Store the

g00323623
elements in a clean, dry location. Illustration 328

10. Install a clean primary filter element. 2. Remove the secondary filter element.

11. Clean the cover. 3. Cover the air inlet opening. Clean the inside of
the air cleaner housing.
12. Install the cover and close the access cover.
4. Uncover the air inlet opening. Install a new
secondary element.

5. Install the primary filter element and the cover.

See Operation and Maintenance Manual, “Engine
Air Filter Primary Element - Clean/Replace” for
the necessary steps.
 171
Maintenance Section
Engine Crankcase Breather Filter - Replace

i01235794

Engine Crankcase Breather

Filter - Replace
SMCS Code: 1317-510
S/N: 6TL1-539
S/N: 6TL542-589
S/N: 6TL592-634
S/N: 7ML1-1060
S/N: 7ML1065-1160 g00306077
Illustration 331
S/N: 7ML1163-1214 (1) Hose
(2) Hose clamp
(3) Elbow

3. Loosen hose clamp (2) and carefully remove

hose (1) from elbow (3).

g00289939
Illustration 329

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

the machine. Secure the access door.

g00306075
Illustration 330

2. Open the access cover that is on the top of the

machine.
172
Maintenance Section
Engine Crankcase Breather Filter - Replace

NOTICE
To prevent damage to the breather valve, remove the
breather valve before the cover is washed.

NOTICE
Ensure that all the cleaning fluid is removed before the
breather is assembled.

11. Use a clean nonflammable solvent in order to

wash the breather body, the valve cover, baffle
plates (7), and elbow (3). Thoroughly dry the
components after cleaning.

12. Make sure that the holes in the bottom of the

chamber for baffle plates (7) are not restricted.
Clean the holes, if necessary.

13. Install baffle plates (7) into the grooves in the

breather body.

14. Install a new breather filter (6) into the breather

body.

15. Reinstall breather valve (4) into the valve cover.

Make sure that clip retainers (5) are engaged
correctly.

16. Install a new gasket (8). The gasket is installed

dry.

17. Place the valve cover and breather valve (4) into
position on the breather body.
g00293186
Illustration 332
(3) Elbow 18. Loosely install the bolts.
(4) Breather valve
(5) Clip retainers 19. Tighten the bolts.
(6) Breather filter
(7) Baffle plates
(8) Gasket NOTICE
Do not use excessive force to fit the hose to the
4. Remove the valve cover. Refer to the Service breather outlet elbow.
Manual for information on removing the valve
cover.
20. Make sure that nothing is restricting the air flow
in elbow (3) or in hose (1).
Note: It may be necessary to use a suitable lever in
order to remove the valve cover. Make sure that the
21. Carefully install hose (1) on elbow (3).
lever does not damage the valve cover.
22. Tighten hose clamp (2).
5. Remove gasket (8).
23. Close the access cover.
6. Discard gasket (8).
24. Close the access door.
7. Release clip retainers (5) on breather valve (4).
Push the breather valve out of the valve cover.

8. Remove breather filter (6).

9. Discard breather filter (6).

10. Remove baffle plates (7).

 173
Maintenance Section
Engine Crankcase Breather Filter - Replace

i01236041

Engine Crankcase Breather

Filter - Replace
SMCS Code: 1317-510
S/N: 6TL540-541
S/N: 6TL590-591
S/N: 6TL635-Up
S/N: 7ML1061-1064
S/N: 7ML1161-1162 g00660532
Illustration 335
S/N: 7ML1215-Up (1) Cap
(2) Hose clamp
(3) Hose
(4) Hose clamp
(5) Hose
(6) Hose clamp
(7) Hose

3. Loosen hose clamps (2) and (4) and carefully

remove hoses (3) and (5).

4. Loosen hose clamp (6) and carefully remove

hose (7) at the bottom of the breather filter
canister.

5. Remove the breather filter canister.

g00289939
Illustration 333 6. Remove cap (1).
1. Open the access door that is on the left side of
the machine. Secure the access door. NOTICE
Ensure that all the cleaning fluid is removed before the
breather is assembled.

7. Use a clean nonflammable solvent in order to

wash the breather canister and the filter mesh.
Thoroughly dry the components after cleaning.

8. Reinstall the cap (1).

NOTICE
Do not use excessive force to fit the hose to the
breather outlet elbow.

9. Make sure that nothing is restricting the air flow

g00518246
Illustration 334 in hoses (3) and (5).

2. Open the access cover that is on the top of the 10. Make sure that nothing is restricting the oil flow
machine. in hose (7).

11. Carefully install hoses (3), (5) and (7).

12. Tighten hose clamps (2), (4) and (6).

13. Close the access cover.

174
Maintenance Section
Engine Crankcase Breather Valve - Replace

14. Close the access door.

i01236331

Engine Crankcase Breather

Valve - Replace
SMCS Code: 1317-510

g00306077
Illustration 338
(1) Hose
(2) Hose clamp
(3) Elbow

3. Loosen hose clamp (2) and carefully remove

hose (1) from elbow (3).

g00289939
Illustration 336

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

the machine. Secure the access door.

g00306075
Illustration 337

2. Open the access cover that is on the top of the

machine.
 175
Maintenance Section
Engine Oil Level - Check

11. Remove baffle plates (7).

NOTICE
Ensure that all the cleaning fluid is removed before the
breather is assembled.

12. Use a clean nonflammable solvent in order to

wash the breather body, the valve cover, baffle
plates (7), and elbow (3). Thoroughly dry the
components after cleaning.

13. Make sure that the holes in the bottom of the

chamber for baffle plates (7) are not restricted.
Clean the holes, if necessary.

14. Install baffle plates (7) into the grooves in the

breather body.

15. Install a new breather filter (6) into the breather

body.

16. Install a new breather valve (4) into the valve

cover. Make sure that clip retainers (5) are
engaged correctly.

17. Install a new gasket (8). The gasket is installed

dry.

18. Place the valve cover and breather valve (4) into
position on the breather body.

19. Loosely install the bolts.

g00293186 20. Tighten the bolts.

Illustration 339
(3) Elbow
(4) Breather valve NOTICE
(5) Clip retainers Do not use excessive force to fit the hose to the
(6) Breather filter breather outlet elbow.
(7) Baffle plates
(8) Gasket
21. Make sure that nothing is restricting the air flow
4. Remove the valve cover. Refer to the Service in elbow (3) or in hose (1).
Manual for information on removing the valve
cover. 22. Carefully install hose (1) on elbow (3).

Note: It may be necessary to use a suitable lever in 23. Tighten hose clamp (2).
order to remove the valve cover. Make sure that the
lever does not damage the valve cover. 24. Close the access cover.

5. Remove gasket (8). 25. Close the access door.

6. Discard gasket (8).

i00707018

7. Release clip retainers (5) on breather valve (4).

Push the breather valve out of the valve cover.
Engine Oil Level - Check
SMCS Code: 1000-535
8. Discard breather valve (4).

9. Remove breather filter (6). NOTICE

Do not overfill the crankcase. Engine damage can re-
10. Discard breather filter (6). sult.
176
Maintenance Section
Engine Oil and Filter - Change

Check the engine oil level while the engine is

stopped.

g00102290
Illustration 342

Illustration 340
g00290071 5. Maintain the oil level below the “FULL RANGE”
mark on the dipstick and above the “ADD” on
1. Open the access cover that is on the right side the dipstick. If the oil level is low, add oil.
of the machine.
Note: If the oil level is above the “FULL RANGE”
mark, operating the engine could cause the
crankshaft to dip into the oil. A crankshaft in the
oil could lead to excessively high oil temperatures.
Excessively high oil temperatures can reduce the
lubricating characteristics of the oil. The reduction
of lubricating characteristics of the oil causes
bearing damage. Bearing damage leads to the loss
of engine power.

Note: Refer to Operation and Maintenance Manual,

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

6. Remove oil filler plug (2) in order to add oil.

g00309923
Illustration 341
(1) Dipstick 7. Add oil, if necessary.
(2) Oil filler plug
8. Clean oil filler plug (2). Install the oil filler plug.

9. Close the access cover.

Hot engine components can cause injury from
burns. Before performing maintenance on the i00706875
engine, allow the engine and the components to
cool. Engine Oil and Filter - Change
SMCS Code: 1318-510
2. Remove dipstick (1) in order to measure the oil
level. 1. Park the machine on a level surface.
Oil which is badly contaminated or badly 2. Engage the parking brake.
deteriorated should be replaced early. Replace
the oil regardless of the time interval. 3. Lower the implements to the ground.
3. Remove the oil from dipstick (1). 4. Stop the engine.
4. Insert dipstick (1). Remove the dipstick again.
 177
Maintenance Section
Engine Oil and Filter - Change

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.

g00309746
Illustration 345
(2) Oil filler plug
(3) Dipstick
(4) Oil filter

g00290071
Illustration 343 Hot engine components can cause injury from
burns. Before performing maintenance on the
5. Open the access cover that is on the right side engine, allow the engine and the components to
of the machine. cool.

7. Remove used oil filter (4). See Operation and

Maintenance Manual, “Oil Filter - Inspect”.

8. Clean the filter housing base. Remove all of the

old filter gasket.

g00309745
Illustration 344
(1) Crankcase drain valve

Note: Refer to the Operation and Maintenance

Manual, “General Hazard Information” for
information in containing fluid spillage.
g00102462
6. Open crankcase drain valve (1). Allow the oil to Illustration 346
drain into a suitable container. Close crankcase
drain valve (1). 9. Apply a thin coat of engine oil to the gasket of
the new filter.
Note: Dispose of drained fluids according to local
regulations. 10. Install the new filter by hand. When the gasket
contacts the filter base, tighten the filter by an
additional 3/4 turn.

Every new oil filter has rotation index marks that

are spaced at increments of 1/4 turn. Use the
rotation index marks as a guide for tightening
the oil filter.
178
Maintenance Section
Engine Valve Lash and Fuel Injector Timing - Check

11. Remove oil filler plug (2). Refer to the Service Manual for the complete
procedure for checking the injector fuel timing or for
NOTICE adjusting the injector fuel timing.
Do not overfill the crankcase. Engine damage can re-
sult. Note: The correct fuel timing specification is
given on the Engine Information Plate. Fuel
timing specifications may differ for distinct engine
12. Fill the crankcase with new oil. applications and/or power ratings.

Note: Refer to the Operation and Maintenance

Manual, “Refill Capacities”. i00312950

13. Clean filler plug (2).

Final Drive Oil - Change
SMCS Code: 4050-044-FLV
14. Install filler plug (2).

15. Start the engine. Run the engine at low idle for
two minutes. Check for oil leaks. Stop the engine.

g00102722
Illustration 348

1. Turn the hub until the fill/drain plug is at the

g00102420 lowest position.
Illustration 347
2. Remove the dirt that is around the fill/drain plug.
16. Wait for ten minutes in order to allow the oil to
drain back into the crankcase. Check the oil Note: Refer to Operation and Maintenance Manual,
level. Maintain the oil level between the “ADD” “General Hazard Information” for information on
mark and “FULL” mark on dipstick (3). containing fluid spillage.
17. Close the access cover. 3. Remove the fill/drain plug. Drain the oil into a
suitable container.
i00707053
Note: Dispose of used oil according to local
Engine Valve Lash and Fuel regulations.
Injector Timing - Check 4. Turn the hub until the opening of the fill/drain
plug is horizontal.
SMCS Code: 1102; 1105-025; 1105; 1290-531-FT;
1290
5. Fill the final drive with lubricant to the bottom of
the opening of the fill/drain plug. See Operation
Refer to the Service Manual for the complete
and Maintenance Manual, “Refill Capacities”.
procedure for checking the engine valve lash. This
procedure lists the steps for the engine valve lash 6. Inspect the O-ring seal. If damage or wear is
adjustment and the steps in order to check the
noticed on the O-ring seal, replace the seal.
engine valve lash.
7. Install the O-ring seal. Install the fill/drain plug.
Note: Make sure that a qualified mechanic works on
the injector fuel timing. Special tools and training
8. Repeat Steps 1 through 7 for the remaining three
are required. axle hubs.
 179
Maintenance Section
Final Drive Oil Level - Check

i00703977
NOTICE
Final Drive Oil Level - Check Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
SMCS Code: 4050-535-FLV will be disconnected. Fit a suitable cover over discon-
nected fuel system component.

1. Shut off the fuel supply.

g00311043
Illustration 349

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information on
containing fluid spillage. Illustration 350 g00290071

1. Turn the hub until the opening of the fill/drain 2. Open the access door on the right side of the
plug is horizontal, as shown. machine.
2. Remove the dirt that is around the fill/drain plug.

3. Fill the final drive with lubricant to the bottom of

the opening of the fill/drain plug. See Operation
and Maintenance Manual, “Refill Capacities”.

4. Inspect the O-ring seal. If damage or wear is

noticed on the O-ring seal, replace the seal.

5. Install the O-ring seal. Install the fill/drain plug.

6. Repeat Steps 1 through 5 for the remaining three

axle hubs.
g00660558
Illustration 351
i01236398
Primary filter/water separator
Fuel System Primary
Filter/Water Separator Element
- Replace
SMCS Code: 1260-510; 1263-510

Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
180
Maintenance Section
Fuel System Priming Pump - Operate

11. Clean the inside surfaces of the filter head and

of bowl (4).

12. Inspect the O-ring on bowl (4). Also inspect the

seal in the filter head. Replace these seals if the
seals are worn or damaged.

13. Push a new filter fully into the filter head.

14. Hold the new filter in place. Fit locking ring (1)
into position. Rotate the locking ring clockwise in
order to fasten the filter to the filter head.

15. Hold bowl (4) in place. Fit locking ring (3) into
g00293655 position. Rotate the locking ring clockwise in
Illustration 352 order to fasten the bowl to the filter.
(1) Locking ring
(2) Filter Note: Do not start the engine until all service to
(3) Locking ring
(4) Bowl the fuel system is complete. For instructions about
priming the fuel system, refer to Operation and
3. Clean the outside of the fuel filter assembly. Maintenance Manual, “Fuel System Priming Pump
- Operate”.
4. Place a tray under the fuel filter in order to catch
any fuel that might spill. Clean up any spilled 16. Close the access door.
fuel immediately.
17. Turn the fuel shutoff valve counterclockwise in
5. Turn the drain that is located at the bottom of order to open the fuel supply.
filter (2) counterclockwise. Drain the fuel and
water into a suitable container. i00708256

Note: Properly dispose of the drained fluids. Obey Fuel System Priming Pump -
local regulations for the disposal of the fluid.
Operate
6. Close the drain valve.
SMCS Code: 1258
NOTICE Priming the fuel system fills the fuel filter. Priming
Do not use a tool in order to remove the fuel filter. the fuel system removes air bubbles from the fuel
Attempting to remove the fuel filter with a filter wrench system. Prime the fuel system under the following
or a filter strap could damage the locking ring. conditions:

7. Hold filter (2) and rotate locking ring (3) • Fuel system that is run dry
counterclockwise.
• Storage
8. Remove bowl (4).
• Fuel filter maintenance
9. Hold filter (2) and rotate locking ring (1)
counterclockwise. • Disconnecting fuel lines and installing fuel lines
10. Remove filter (2) and discard filter (2). • Repair of leaks in the fuel lines

NOTICE
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel Fuel leaked or spilled onto hot surfaces or elec-
system parts. trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Note: The primary filter/water separator is a Clean up fuel spills immediately.
cartridge type filter. The filter cannot be reused.
 181
Maintenance Section
Fuel System Priming Pump Strainer - Clean

NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.

g00286062
Illustration 355

3. Loosen two of the fuel line nuts at two of the fuel

injection nozzles in order to open two vents.
g00290071
Illustration 353
NOTICE
Do not crank the engine continuously for more than
NOTICE 30 seconds. Allow the starting motor to cool for two
Do not allow dirt to enter the fuel system. Thoroughly minutes before cranking the engine again.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component. 4. Crank the engine until the flow of fuel from the
vents is continuous and free of air bubbles.
Tighten the fuel line nuts.
1. Open the access cover on the right hand side of
the machine. 5. Ensure that all fuel line connections are secure
and tightened to the proper torque. Ensure that
any spilled fuel is cleaned up.

6. Start the engine. The engine may run rough. Run

the engine at low idle until the engine runs well.
If the engine will not start, further priming may be
necessary. If the engine starts and if the engine
continues to misfire or smoke, one or more of the
following conditions may be present:

• The fuel system requires more priming.

• There may be an air leak in the fuel system.

Illustration 354
g00286060 7. Close the access cover.

2. When the engine is cold, operate the priming i00708354

lever for 2 minutes or operate the priming lever
until resistance is felt. Fuel System Priming Pump
Strainer - Clean
SMCS Code: 1258

The strainer in the fuel system priming pump should

be cleaned when a loss of power from the engine
is noticed.
182
Maintenance Section
Fuel System Secondary Filter - Replace

4. Use nonflammable solvent in order to clean the

strainer, the cover, and the seal. Carefully wash
any sediment from the chamber of the fuel lift
Fuel leaked or spilled onto hot surfaces or elec-
pump.
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
5. Assemble the clean, dry fuel priming pump.
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Ensure that the lift pump cover is secure so that air
NOTICE does not enter the fuel system.
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon- 6. Prime the fuel system. Refer to the Operation
nected fuel system component. and Maintenance Manual, “Fuel System Priming
Pump - Operate” in the Maintenance Section for
more information on priming the fuel system.

7. Install the heat shield (if equipped).

8. Close the access cover.

i01236455

Fuel System Secondary Filter -

Replace
SMCS Code: 1261-510

g00290071
Illustration 356

1. Open the access cover on the right hand side of Fuel leaked or spilled onto hot surfaces or elec-
the machine. trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.

g00286056
Illustration 357
(1) Fuel priming pump. (2) Cover and seal. (3) Strainer.

Note: It may be necessary to remove the heat shield

(if equipped) that is between the priming pump and
the turbocharger.

2. Remove the cover and seal (2) from the top of

fuel priming pump (1).
g00290071
3. Remove strainer (3). Illustration 358
 183
Maintenance Section
Fuel System Water Separator - Drain

1. Open the access cover on the right hand side of 11. Prime the fuel system. Refer to Operation and
the machine. Maintenance Manual, “Fuel System Priming
Pump - Operate” in the Maintenance Section for
more information.

12. Close the access cover.

i01236507

Fuel System Water Separator

- Drain
SMCS Code: 1263

g00660563
Illustration 359
Secondary filter

2. Clean the outside of the fuel filter assembly.

3. Place a tray under the fuel filter in order to catch

any fuel that might spill. Clean up any spilled
fuel immediately.

4. Turn the drain that is located at the bottom of the

filter counterclockwise. Drain the fuel and water
into a suitable container. g00290071
Illustration 360
Note: Properly dispose of the drained fluids. Obey
local regulations for the disposal of the fluid. 1. Open the access door on the right side of the
machine.
5. Close the drain valve.

NOTICE
Do not use a tool in order to remove the fuel filter.
Attempting to remove the fuel filter with a filter wrench
or a filter strap could damage the locking ring.

6. Hold the filter and rotate the locking ring

counterclockwise. Remove the locking ring. The
used filter should be removed and discarded.

NOTICE
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel Illustration 361
g00660558
system parts.
Primary filter/water separator

7. Ensure that the filter head is clean.

8. Inspect the seal in the filter head. Replace the

seal if the seal is worn or damaged.

9. Push a new filter fully into the filter head.

10. Hold the new filter in place. Fit the locking ring
into position. Rotate the locking ring clockwise in
order to fasten the filter to the filter head.
184
Maintenance Section
Fuel Tank Cap and Strainer - Clean

Bodily injury can occur from unexpected contact

with open cab doors on machines equipped with
a fixed cab riser.

To avoid injury, close the cab door before climbing

onto the rear of the machine.

g00293673
Illustration 362

2. Turn the drain valve that is located at the

bottom of the primary filter/water separator
counterclockwise.

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information on
containing fluid spillage.
g00311210
Illustration 364
3. Drain the water and drain the sediment into a
suitable container. 2. Remove the fuel tank cap and the fuel fill screen.

Note: Dispose of drained fluids according to local 3. Wash the fuel fill screen and wash the fuel tank
regulations. cap. Refer to the next two topics.

4. Close the drain valve. 4. Install the screen into the filler opening.

5. Close the access door. 5. Install the fuel tank cap.

6. Close the access door.

i00995189

Fuel Tank Cap and Strainer - Type 1 Fuel Tank Cap

Clean 1. Inspect the gasket for damage. Replace the cap
SMCS Code: 1273-070-STR if the gasket is damaged.

2. Wash the fuel fill screen and wash the fuel

tank cap. Wash these components in a clean,
nonflammable solvent.

g00289939
Illustration 363

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

the machine. Secure the access door.
 185
Maintenance Section
Fuel Tank Water and Sediment - Drain

Type 2 Fuel Tank Cap

g00294897
Illustration 366
g00102605
Illustration 365
The fuel tank is on the left side of the machine. The
(1) Screws
(2) Filter Assembly drain valve is under the fuel tank.
(3) Valve
(4) Gasket 1. Remove the cover under the fuel tank in order to
access the drain valve.
1. Inspect gasket (4) for damage. Replace the
gasket, as needed.

2. Remove the following items: screws (1), filter

assembly (2), valve (3), and gasket (4).

3. Wash the fuel fill screen and wash the fuel

cap. Wash these components in a clean,
nonflammable solvent.

i00995193

Fuel Tank Water and Sediment

- Drain g00102343
Illustration 367
SMCS Code: 1273-543
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information in
Containing Fluid Spillage.
Personal injury or death can result from a fire. 2. Remove the cap that is on the bottom of the
drain valve. Open the drain valve in order to
Fuel leaked or spilled onto hot surfaces or electri- drain the water and the sediment. Drain these
cal components can cause a fire. foreign materials into a suitable container.
Clean up all leaked or spilled fuel. Do not smoke Note: Always dispose of drained fluid according to
while working on the fuel system. local regulations.
Turn the disconnect switch OFF or disconnect the 3. Close the drain valve and install the cap. Install
battery when changing fuel filters. the cover over the drain valve.
186
Maintenance Section
Fuses - Replace

Fill the Fuel Tank

g00102346
Illustration 370
g00289939
Illustration 368
3. Add fuel until the fuel level is in the sight gauge.
1. Open the access door and secure the access The sight gauge is located inside the access
door on the left side of the machine. cover on the left side of the machine.

4. Replace the fuel tank filler cap. To protect against

vandalism, lock the fuel filler cap.
Bodily injury can occur from unexpected contact
5. Close the access door and close the access
with open cab doors on machines equipped with
cover.
a fixed cab riser.

To avoid injury, close the cab door before climbing i00709254

onto the rear of the machine.
Fuses - Replace
SMCS Code: 1417-510

Fuses – The fuses protect the electrical

system from damage that is caused
by overloads. If the element separates,
change the fuse. If the element of the new fuse
separates, check the circuit and repair the circuit.

NOTICE
Always replace fuses with the same type and capacity
fuse that was removed. Otherwise, electrical damage
could result.
g00102345
Illustration 369
NOTICE
Note: Refer to Operation and Maintenance Manual, If it is necessary to replace fuses frequently, an elec-
“General Hazard Information” for information in trical problem may exist.
Containing Fluid Spillage.
Contact your Caterpillar dealer.
2. To add fuel, remove the fuel filler cap.

Note: Fuel can also be added to the tank by using

the electric refueling pump (if equipped). Refer to
Operation and Maintenance Manual, “Refueling
Pump” for instructions on operating the electric
refueling pump.
 187
Maintenance Section
Fuses - Replace

Yellow Fuse Block

g00294897
Illustration 371
g00311792
Illustration 373
Open the access cover on the left side of the
machine. Electrical Fuel Lift Pump (9) – 25 Amp

The following fuses protect the listed circuits. The Warning Light (10) – 7.5 Amp
amperage of each fuse is also listed.
Engine Start Switch, Main Power Relay and Main
Black Fuse Block Power Light (11) – 15 Amp

24 Volt to 12 Volt Converter and Radio (12) – 7.5

Amp

Start/Stop Relay and Starting Aid(13) – 7.5 Amp

Air Horn Compressor (14) – 15 Amp

Heater Fan (15) – 15 Amp

Lighter, Plug, and Dome Light (16) – 7.5 Amp

Green Fuse Block

g00311789
Illustration 372

Right Side Parking Lights (1) – 7.5 Amp

Left Side Parking Lights (2) – 7.5 Amp

Instrument Lights (3) – 7.5 Amp

Right Side Low Beam Lights (4) – 7.5 Amp

Left Side Low Beam Lights (5) – 7.5 Amp

Right Side High Beam Lights (6) – 7.5 Amp

g00311794
Illustration 374
Left Side High Beam Lights (7) – 7.5 Amp
Backup Alarm (17) – 7.5 Amp
Control Lights and Turn Signal (8) – 7.5 Amp
Power Mode Selection (18) – 7.5 Amp

Individual Stabilizers (19) – 7.5 Amp

Working Lights (20) – 15 Amp

188
Maintenance Section
Fuses - Replace

Frequency Adjustment for Hammer Blow and Flow Additional Fuses

Control (21) – 7.5 Amp
Fuse for Main Power
Electronics (22) – 7.5 Amp

Rotating Beacons (23) – 15 Amp

Pneumatic Operator Seat and Priority (24) – 7.5

Amp

Red Fuse Block

g00311798
Illustration 376
An additional fuse is positioned in the fuse box.

Main Power (33) – 60 Amp

Fuse For Starter Motor And For Alternator

g00311796
Illustration 375

Stop Light (25) – 7.5 Amp

Air Conditioner (26) – 20 Amp

Horn, Overload Buzzer and Third Pressure Drop

Warning Buzzer (27) – 7.5 Amp

Reverse Steering Warning Light and Travel Alarm

(28) – 7.5 Amp

Switch for Armrest, Swing Brake, Miscellaneous

g00290071
Function, Travel Cutoff Relay, Park Brake, Illustration 377
Transmission Speed, and Creeper Speed (29) – 15 This fuse is located behind the access cover that is on the right
Amp side of the machine.

Supplemental Steering (30) – 7.5 Amp

Upper Windshield Wiper and Pump (31) – 7.5 Amp

Lower Windshield Wiper and Pump (32) – 7.5 Amp

g00311799
Illustration 378

Starter Motor and Alternator (34) – 70 Amp

 189
Maintenance Section
Hydraulic System Oil - Change

i00995196

Hydraulic System Oil - Change

SMCS Code: 5056-044
S/N: 6TL1-Up

Drain the Oil

1. Operate the machine for an adequate period of
time in order to warm the oil.

2. Park the machine on a level surface.

g00312243
3. Engage the parking brake. Illustration 380

4. Lower the implements to the ground with the 7. Open the access cover on the top of the
stick in a vertical position, as shown. machine.

5. Stop the engine.

g00312244
Illustration 381

Illustration 379
g00289939 8. Slowly loosen the breather in order to relieve
system pressure.
6. Open the access door on the left side of the
machine. Secure the access door.

Bodily injury can occur from unexpected contact

with open cab doors on machines equipped with
a fixed cab riser.

To avoid injury, close the cab door before climbing

onto the rear of the machine.

g00312245
Illustration 382
The drain valve is under the middle of the machine.

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information in
containing fluid spillage.
190
Maintenance Section
Hydraulic System Oil - Change

9. Remove the cap at the bottom of the drain valve. 4. Install the filler plug.
Open the drain valve. Allow the oil to drain into a
suitable container. 5. Start the engine. Operate the engine at idling
speed for a few minutes.
Note: Dispose of drained fluids according to local
regulations. 6. Operate the control levers in order to allow the
hydraulic oil to circulate through all hydraulic
10. Close the drain valve. Install the cap. circuits.

11. Tighten the breather in Step 8. Note: Air may become trapped in the hydraulic
system. The pump may cavitate or the machine
Service the Hydraulic System may move in jerks for several seconds. If these
symptoms continue then air is trapped in the
Filters hydraulic system. Refer to Testing and Adjusting,
RENR1180, “Hydraulic System Pressure - Release”
Note: The hydraulic oil system must be empty when for instructions on releasing the air.
the filters are being serviced. Service the filters
before refilling the machine with hydraulic oil. 7. Lower the implement to the ground. The stick
should be vertical.
Refer to the following topics in order to service the
hydraulic system filters: 8. Stop the engine.

• Operation and Maintenance Manual, “Hydraulic

System Oil Filter - Clean (Return In-line Filters)”

• Operation and Maintenance Manual, “Hydraulic

System Oil Filter - Replace (Hydraulic Swing
Circuit Filter)”

• Operation and Maintenance Manual, “Hydraulic

System Oil Filter - Replace (Pilot Filter)”

• Operation and Maintenance Manual, “Hydraulic

System Oil Filter - Replace (Return Filter)”

Fill the Hydraulic Tank Illustration 384

g00311264

The sight gauge is located in the engine compartment on the right

side of the machine.

9. Maintain the oil level to the “0” mark on the sight

gauge. The number on the sight gauge indicates
the quantity of oil in liters that is needed to fill
the tank.

10. Install the cover under the hydraulic tank.

11. Close all access covers and access doors.

Secure all access covers and access doors.

g00312371
Illustration 383

1. Remove the filler plug from the hydraulic tank.

2. Fill the hydraulic oil tank. See Operation and

Maintenance Manual, “Refill Capacities”.

3. Clean the filler plug. Inspect the O-ring seal.

Replace the O-ring seal if the seal is worn or
damaged.
 191
Maintenance Section
Hydraulic System Oil - Change

i00995199

Hydraulic System Oil - Change

SMCS Code: 5056-044
S/N: 7ML1-Up

Drain the Oil

1. Operate the machine for an adequate period of
time in order to warm the oil.

2. Park the machine on a level surface.

g00312243
3. Engage the parking brake. Illustration 386

4. Lower the implements to the ground with the 7. Open the access cover on the top of the
stick in a vertical position, as shown. machine.

5. Stop the engine.

g00314243
Illustration 387

Illustration 385
g00289939 8. Slowly loosen the breather in order to relieve
system pressure.
6. Open the access door on the left side of the
machine. Secure the access door.

Bodily injury can occur from unexpected contact

with open cab doors on machines equipped with
a fixed cab riser.

To avoid injury, close the cab door before climbing

onto the rear of the machine.

g00312245
Illustration 388
The drain valve is under the middle of the machine.

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information in
containing fluid spillage.
192
Maintenance Section
Hydraulic System Oil - Change

9. Remove the cap at the bottom of the drain valve. 4. Install the filler plug.
Open the drain valve. Allow the oil to drain into a
suitable container. 5. Start the engine. Operate the engine at idling
speed for a few minutes.
Note: Dispose of drained fluids according to local
regulations. 6. Operate the control levers in order to allow the
hydraulic oil to circulate through all hydraulic
10. Close the drain valve. Install the cap. circuits.

11. Tighten the breather in Step 8. Note: Air may become trapped in the hydraulic
system. The pump may cavitate or the machine
Service the Hydraulic System may move in jerks for several seconds. If these
symptoms continue then air is trapped in the
Filters hydraulic system. Refer to Testing and Adjusting,
RENR1181, “Hydraulic System Pressure - Release”
Note: The hydraulic oil system must be empty when for instructions on releasing the air.
the filters are being serviced. Service the filters
before refilling the machine with hydraulic oil. 7. Lower the implement to the ground. The stick
should be vertical.
Refer to the following topics in order to service the
hydraulic system filters: 8. Stop the engine.

• Operation and Maintenance Manual, “Hydraulic

System Oil Filter - Clean (Return In-line Filters)”

• Operation and Maintenance Manual, “Hydraulic

System Oil Filter - Replace (Hydraulic Swing
Circuit Filter)”

• Operation and Maintenance Manual, “Hydraulic

System Oil Filter - Replace (Pilot Filter)”

• Operation and Maintenance Manual, “Hydraulic

System Oil Filter - Replace (Return Filter)”

Fill the Hydraulic Tank Illustration 390

g00311264

The sight gauge is located in the engine compartment on the right

side of the machine.

9. Maintain the oil level to the “0” mark on the sight

gauge. The number on the sight gauge indicates
the quantity of oil in liters that is needed to fill
the tank.

10. Install the cover under the hydraulic tank.

11. Close all access covers and access doors.

Secure all access covers and access doors.

g00314246
Illustration 389

1. Remove the filler plug from the hydraulic tank.

2. Fill the hydraulic oil tank. See Operation and

Maintenance Manual, “Refill Capacities”.

3. Clean the filler plug. Inspect the O-ring seal.

Replace the O-ring seal if the seal is worn or
damaged.
 193
Maintenance Section
Hydraulic System Oil Filter - Clean

i00764909 5. Install in-line filter (1) and in-line filter (3). Install
the in-line filter into the holders.
Hydraulic System Oil Filter -
Clean 6. Connect the hydraulic lines.
(Return In-line Filters)
i00764914
SMCS Code: 5068-070
Hydraulic System Oil Filter -
Note: The hydraulic oil system must be empty when Replace
the filters are being serviced. Refer to Operation
and Maintenance Manual, “Hydraulic System Oil (Pilot Filter)
- Change”.
SMCS Code: 5068-510
S/N: 6TL1-409
S/N: 7ML1-859

Note: The hydraulic oil system must be empty when

the filter is being serviced. Refer to Operation
and Maintenance Manual, “Hydraulic System Oil
- Change”.

g00312363
Illustration 391
In-line filter (1) is positioned at the right rear of hydraulic tank (2).

g00312367
Illustration 393

1. Open the top access cover.

g00312366
Illustration 392
In-line filter (3) is positioned between the swing motor and the
swivel.

1. Separate the hydraulic lines at in-line filter (1)

and at in-line filter (3).

2. Remove the in-line filter from the holders.

3. Wash the in-line filter in a clean, nonflammable

g00312368
solvent. Allow the in-line filter to dry. Illustration 394
The pilot filter is located below the pilot manifold.
4. Clean the holders. Inspect the O-ring seals of
the holders. If damage or wear is found, replace
the O-ring seals.
194
Maintenance Section
Hydraulic System Oil Filter - Replace

g00312369 g00312246
Illustration 395 Illustration 396
Typical Example (1) Nuts
(2) Filter Cover
2. Remove the filter housing.
1. Remove four nuts (1) and lock washers. Remove
3. Remove the filter element. Discard the filter filter cover (2).
element.
2. Remove the filter element. Discard the filter
Note: Dispose of used filter elements according to element.
local regulations.
Note: Dispose of used filter elements according to
4. Clean the filter housing. local regulations.

5. Install a new filter element in the filter housing. 3. Install a new filter element.

6. Install the filter housing. 4. Clean filter cover (2). Inspect the cover seal. If
damage or wear is found, replace the cover seal.
i00765062 5. Install filter cover (2). Install four lock washers
and nuts (1).
Hydraulic System Oil Filter -
Replace i00765078
(Return Filter) Hydraulic System Oil Filter -
SMCS Code: 5068-510 Replace
S/N: 6TL1-Up (Hydraulic Swing Circuit Filter)
Note: The hydraulic oil system must be empty when SMCS Code: 5068-510
the filter is being serviced. Refer to Operation
and Maintenance Manual, “Hydraulic System Oil Note: The hydraulic oil system must be empty when
- Change”. the filter is being serviced. Refer to Operation
and Maintenance Manual, “Hydraulic System Oil
- Change”.
 195
Maintenance Section
Hydraulic System Oil Filter - Replace

i00703730

Hydraulic System Oil Filter -

Replace
(Pilot Filter)
SMCS Code: 5068-510
S/N: 6TL410-Up
S/N: 7ML860-Up

Note: The hydraulic oil system must be empty when

the filter is being serviced. Refer to Operation
Illustration 397
g00290071 and Maintenance Manual, “Hydraulic System Oil
- Change”.
The hydraulic swing circuit filter is in the engine compartment on
the right side of the machine.
Note: The pilot filter is located under the operator
1. Open the access cover on the right side of the compartment.
machine.
1. Remove the lower access cover.

g00312370
Illustration 398 g00290375
Illustration 399
2. Remove the filter housing.
2. Clean the area in order to prevent dirt from
3. Remove the filter element. Discard the filter entering the filter base.
element.
3. Remove the used pilot filter element from the
Note: Dispose of used filter elements according to filter base.
local regulations.
4. Remove the filter element. Dispose of the used
4. Clean the filter housing. Inspect the O-ring seal filter element.
of the filter housing. Replace the seal if the seal
is worn or damaged. Note: Dispose of used filter elements according to
local regulations.
5. Install a new filter element in the filter housing.
5. Clean the filter base.
6. Install the filter housing.

7. Close the access cover on the right side of the

machine.
196
Maintenance Section
Hydraulic System Oil Filter - Replace

1. Remove four nuts (1) and lock washers. Remove

filter cover (2).

2. Remove the filter element. Discard the filter

element.

Note: Dispose of used filter elements according to

local regulations.

3. Install a new filter element.

4. Clean filter cover (2). Inspect the cover seal. If

damage or wear is found, replace the cover seal.

g00101502 5. Install filter cover (2). Install four lock washers

Illustration 400 and nuts (1).
6. Install the new filter by hand. When the gasket
contacts the filter base, tighten the filter by an i00708361
additional 3/4 turn.
Hydraulic System Oil Level -
Every new oil filter has rotation index marks that Check
are spaced at 1/4 turn. Use the rotation index
marks as a guide for tightening the oil filter. SMCS Code: 5050-535
7. Install the lower access cover. S/N: 6TL1-Up

i00765075

Hydraulic System Oil Filter -

Replace
(Return Filter)
SMCS Code: 5068-510
S/N: 7ML1-Up

Note: The hydraulic oil system must be empty when

the filter is being serviced. Refer to Operation
and Maintenance Manual, “Hydraulic System Oil g00290071
- Change”. Illustration 402

1. Open the access cover that is on the right side

of the machine.

2. Lower the dozer (if equipped) and stabilizers (if

equipped) to the ground.

3. Place the stick in the vertical position. Place the

bucket on the ground. This position is shown in
Illustration402.

g00314245
Illustration 401
(1) Nuts
(2) Filter Cover
 197
Maintenance Section
Hydraulic System Oil Level - Check

g00311264 g00311265
Illustration 403 Illustration 405
(3) Breather
4. Maintain the oil level to the “0” mark on the sight (4) Filler Plug
gauge. The numbers on the sight gauge indicate
the number of liters of oil that must be added in 6. Slowly loosen breather (3) in order to relieve the
order to fill the system. system pressure. Remove filler plug (4). Add the
oil through the filler tube.

7. Clean filler plug (4). Install the filler plug. Replace

the seal O-ring if the O-ring is worn or damaged.

8. Tighten breather (3).

9. Close the access covers and the access door.

i00708535

Hydraulic System Oil Level -

Check
g00290119
Illustration 404 SMCS Code: 5050-535
(1) Access Door
(2) Top Access Cover S/N: 7ML1-Up

Note: Refer to Operation and Maintenance Manual,

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

5. If the system needs oil, add the necessary

amount of oil. Open the access door (1) that
is on the left side of the machine. Secure the
access door (1). Open the access cover (2) on
the top of the machine.

g00290071
Illustration 406

1. Open the access cover that is on the right side

of the machine.

2. Lower the dozer (if equipped) and stabilizers (if

equipped) to the ground.
198
Maintenance Section
Oil Filter - Inspect

3. Place the stick in the vertical position. Place the

bucket on the ground. This position is shown in
Illustration 406.

g00311443
Illustration 409
(3) Breather
(4) Filler Plug
g00311264
Illustration 407
6. Slowly loosen breather (3) in order to relieve the
4. Maintain the oil level to the “0” mark on the sight system pressure. Remove filler plug (4). Add the
gauge. The numbers on the sight gauge indicate oil through the filler tube.
the number of liters of oil that must be added in
order to fill the system. 7. Clean filler plug (4). Install the filler plug. Replace
the seal O-ring if the O-ring is worn or damaged.

8. Tighten breather (3).

9. Close the access covers and the access door.

i00052234

Oil Filter - Inspect

SMCS Code: 1308-507; 5068-507

Inspect A Used Filter for Debris

g00290119
Illustration 408
(1) Access Door
(2) Top Access Cover

Note: Refer to Operation and Maintenance Manual,

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

5. If the system needs oil, add the necessary

amount of oil. Open the access door (1) that
is on the left side of the machine. Secure the
access door (1). Open the access cover (2) on
the top of the machine.
g00100013
Illustration 410
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.
 199
Maintenance Section
Overhead Guard - Inspect

If metals are found in the filter element, a magnet Do not repair the overhead guard by welding
can be used to differentiate between ferrous metals reinforcement plates to the overhead guard.
and nonferrous metals.
Consult your Caterpillar dealer for repair of cracks
Ferrous metals can indicate wear on steel parts and in the welds on the overhead guard. Consult your
on cast iron parts. Caterpillar dealer for repair of cracks in any metal
section of the overhead guard.
Nonferrous metals can indicate wear on the
aluminum parts of the engine such as main
i01220682
bearings, rod bearings, or turbocharger bearings.

Small amounts of debris may be found in the filter

Radiator Core - Clean
element. This could be caused by friction and by SMCS Code: 1353-070
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.

i00699883

Overhead Guard - Inspect

(If Equipped) Illustration 412
g00379606

(1) Standard radiator access cover

SMCS Code: 7159-040 (2) Hex head screw

1. Remove foreign material from the radiator access

cover (1).

2. Unlock the two hex head screws (2) and rotate

up the radiator access cover (1) .

g00102876
Illustration 411

1. Inspect the overhead guard for any bolts that

are loose or damaged. Replace bolts that are
damaged or missing. Use original equipment
parts only. Tighten the bolts.
g00652861
Illustration 413
Note: Apply oil to all the bolt threads before you
(3) Baffles
install the bolts. Failure to oil the threads can cause
improper bolt torque.
3. Remove baffles (3).
2. If the overhead guard rattles during machine
operation or if the overhead guard makes noises
during machine operation, replace the mounting
supports for the overhead guard.
200
Maintenance Section
Refueling Pump Strainer - Clean

Note: The sound suppression cover (5) will rotate

with the radiator access cover (1).

i00688010

Refueling Pump Strainer -

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

g00652838
Illustration 414

4. Check radiator fins (4) and screen (5) for debris.

5. Remove foreign material from the radiator fins

g00294897
(4) and from screen (5). Illustration 416

Note: To remove dust from a radiator and debris 1. Open the access cover on the left side of the
from a radiator, compressed air is preferred. High machine.
pressure water can be used and steam can also be
used. Clean the radiator, as needed.

See Special Publication, SEBD0518, “Know Your

Cooling System” for detailed information on cleaning
the radiator fins.

Enclosure for Radiator (If Equipped)

g00102274
Illustration 417
(1) Screen
(2) Coupling

2. Remove screen (1) from coupling (2).

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information in
g00378632
containing fluid spillage.
Illustration 415
(5) Sound Suppression Cover 3. Wash screen (2) in a clean, nonflammable
solvent. Dry the screen.
If the machine has a sound suppression cover (5),
it may not be possible to easily access the radiator 4. Install the screen to coupling (2).
core. If it is not possible to access the radiator core,
then refer to step 2. 5. Close the access cover.
 201
Maintenance Section
Seat Belt - Inspect

i00060103 i00699946

Seat Belt - Inspect Stabilizer Bearings - Lubricate

SMCS Code: 7327-040
(If Equipped)
SMCS Code: 7222-086-BD

Wipe all fittings before you apply the grease.

Note: Perform the following procedure for each

stabilizer.

g00102359
Illustration 418

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 g00102409
Illustration 420
machine and “SAE J386 JUN93”. Consult your
Caterpillar dealer for all replacement parts.
Apply lubricant to the one fitting that is on the pin
for the stabilizer pad.
Replace the seat belt after three year of usage
regardless of appearance.
Apply lubricant to one fitting that is on the pin for
the stabilizer arm.
The seat belt and the mounting hardware must
be inspected for wear and for damage before
Apply lubricant to the fitting that is on the rod end
operating the machine. Replace the belt or the
of the stabilizer cylinder.
mounting hardware if wear or damage is found.
Apply lubricant to the fitting on the pin at the head
i00731002 end of the stabilizer cylinder.

Seat Belt - Replace

i00060418
SMCS Code: 7327-510
Swing Bearing - Lubricate
SMCS Code: 7063-086

g00037721
Illustration 419

Regardless of the appearance, replace the seat belt g00102507

Illustration 421
once during every three year interval.
202
Maintenance Section
Swing Gear - Lubricate

Apply grease to the two rearward fittings that are

positioned by the head end of the right boom
cylinder. Apply grease to the fitting until the grease
overflows the bearing seal.

i00995226

Swing Gear - Lubricate

SMCS Code: 7063-086

NOTICE
Improper lubrication can cause damage to machine
components.
g00290391
Illustration 423
To avoid damage, make sure that the proper amount (1) Bolts
of grease is applied to the swing drive. (2) Bumper springs
(3) Cover
When the amount of grease in the compartment be- (4) Gasket
comes too large, the agitation loss becomes large,
thereby accelerating grease deterioration. 2. Remove bolts (1) and bumper springs (2).
Remove cover (3) and gasket (4).
Grease deterioration can cause damage to the pinion
gear of the swing drive and swing internal gear. 3. Inspect gasket (4). Replace the gasket if damage
is evident.
Not enough grease will result in poor gear lubrication.
4. Check the level of grease. The grease should be
evenly distributed on the floor of the pan.

Note: 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.

5. Check for contamination and for discolored

grease.

g00519844
Illustration 422

1. Remove the inspection cover that is located near

the boom base. Inspect the grease.

g00309463
Illustration 424
(5) Plug
(6) O-ring seal
 203
Maintenance Section
Tire Inflation - Check

6. If the grease is contaminated or if the grease i01011331

is discolored with water, change the grease.
Remove plug (5) in order to allow the water Transmission Oil - Change
to drain. When you reinstall plug (5), inspect
the O-ring seal (6). Replace the O-ring seal if SMCS Code: 3080-044; 3080
damage is evident.

7. Raise the boom. Turn the upper structure by 1/12

of a turn. This is the same angle as the angle
between the hours of an analog clock. Lower the
implement to the ground.

8. Repeat Step 4 to Step 7 twelve times. Add

grease, as needed.

9. Install gasket (4), cover (3), bumper springs (2)

and bolts (1).

i00735307
g00102674
Illustration 426
Tire Inflation - Check (1) Filler plug
(2) Drain plug
SMCS Code: 4203-535-AI; 4203-535-PX
Operate the machine for an adequate amount of
time in order to warm the lubricant.

1. Remove the dirt that is around filler plug (1) and

around drain plug (2).

2. Remove drain plug (2). Drain the lubricant into a

suitable container.

Note: Dispose of any used lubricants according to

local regulations.

3. Clean drain plug (2).

g00102393 4. Inspect the O-ring seal. If damage or wear is

Illustration 425 noticed on the O-ring seal, replace the seal.
Measure the air pressure on each tire. Consult your 5. Install drain plug (2).
Caterpillar dealer for the correct load rating and for
the correct operating pressures. 6. Remove filler plug (1).
If necessary, inflate the tires. See Operation and 7. Fill the gearbox with lubricant to the bottom
Maintenance Manual, “Tire Inflation Information”. of the filler plug opening. See Operation and
Maintenance Manual, “Refill Capacities”.

8. Clean filler plug (1).

9. Inspect the O-ring seal. If damage or wear is

noticed on the O-ring seal, replace the seal.

10. Install filler plug (1).

204
Maintenance Section
Transmission Oil Level - Check

i01225442 1. Turn the engine start switch key to the ON

position in order to perform the test.
Transmission Oil Level - Check
SMCS Code: 3080

g00102376
Illustration 429
(1) Service brake
g00655082 (2) Travel speed pedal
Illustration 427
(1) Filler plug 2. Apply service brake (1). Depress travel speed
pedal (2) for forward travel or for reverse travel.
1. Remove filler plug (1).

2. Check the lubricant level. The lubricant level

should be at the bottom of the opening for filler
plug (1).

3. If necessary, fill the gearbox with lubricant to the

bottom of the opening for filler plug (1).

4. Clean filler plug (1).

5. Inspect the O-ring seal. If damage or wear is

noticed on the O-ring seal, replace the seal.

6. Install filler plug (1).

g00102377
Illustration 430

i00700594 (3) Travel alarm cancel switch

Travel Alarm - Test The travel alarm should sound immediately. The
alarm will sound until the travel speed pedal is
(If Equipped) released or until travel alarm cancel switch (3)
is depressed. The travel alarm will sound for a
SMCS Code: 7429-081 minimum of 10 ± 4 seconds.

g00102374
Illustration 428
 205
Maintenance Section
V-Belts - Inspect/Adjust/Replace

i00714139

V-Belts - Inspect/Adjust/
Replace
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

Your engine can be equipped with an alternator

belt, with a fan drive belt and with accessory
drive belts. For maximum engine performance and
maximum utilization of your engine, inspect the
belts for wear and for cracking. Check the belt Illustration 432
g00305688
tension. Adjust the belt tension in order to minimize
belt slippage. Belt slippage will decrease the belt 2. Open the access cover on the top of the
life. Belt slippage will also cause poor performance machine.
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.

g00315873
Illustration 433
(1) Mounting bolt. (2) Alternator. (3) Bracket bolt.

3. Check the belt tension.

Note: 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).
g00289939
Illustration 431
4. To adjust the alternator belt and the fan belt,
loosen bracket bolt (3) and mounting bolt (1) on
Alternator Belt and Fan Belt the alternator bracket.

1. Open the access door on the left side of the 5. To achieve the correct adjustment, move the
machine. Secure the access door. alternator (2) inward or move the alternator (2)
outward, as required.

6. If necessary, use a pry bar in the square hole in

Bodily injury can occur from unexpected contact the mounting bracket in order to move alternator
with open cab doors on machines equipped with (2) to the correct position.
a fixed cab riser.
7. When the adjustment is correct, tighten mounting
To avoid injury, close the cab door before climbing bolt (1) and bracket bolt (3).
onto the rear of the machine.
8. If new belts are installed, check the belt
adjustment again after 30 minutes of engine
operation at the rated speed.
206
Maintenance Section
Walk-Around Inspection

Air Conditioner Belt i00995282

NOTICE
Walk-Around Inspection
The V-belt must be tensioned correctly. Failure to ten- SMCS Code: 7000
sion the belt properly could cause damage to the belt
and/or to the air conditioner compressor.
NOTICE
Accumulated grease and oil on a machine is a fire haz-
ard. Remove this debris with steam cleaning or high
pressure water, at least every 1000 hours or each time
any significant quantity of oil is spilled on a machine.

NOTICE
Spray cleaning the machine with the engine access
cover open and engine running could result in engine
damage.

To avoid engine damage, always shut the engine down

and cover the engine air inlet opening before spray
cleaning with the hood open.
g00315876
Illustration 434
(1) Mounting bolt. (2) Compressor. (3) Bracket bolt.
Note: Watch closely for leaks. If you observe a leak,
find the source of the leak and correct the leak. If
1. Check the belt tension. you suspect a leak or you observe a leak, check
the fluid levels more frequently. Refer to Operation
Note: To check the belt tension, apply 110 N and Maintenance Manual, “Maintenance Interval
(25 lb) of force midway between the pulleys. Schedule” for the correct intervals.
Correctly adjusted belts will deflect 13 to 19 mm
(1/2 to 3/4 inch). Check the implement cylinders and the linkage.
Repair these components if these components are
2. To adjust the air conditioner belt, loosen damaged or excessively worn.
bracket bolt (3) and mounting bolt (1) on the air
conditioner assembly. Inspect the lights for broken bulbs and for broken
lenses. Replace any broken bulbs or broken lenses.
3. To achieve the correct adjustment, move the
compressor (2) inward or move the compressor Inspect the engine compartment. Remove any trash
(2) outward, as required. buildup that is in the engine compartment.

4. If necessary, use a pry bar in order to move Inspect the cooling system for leaks, for faulty
compressor (2) to the correct position. hoses, and for any trash buildup. Correct any leaks
and remove any trash from the radiator.
5. When the adjustment is correct, tighten mounting
bolt (1) and bracket bolt (3). Inspect all belts. Replace any belts if the following
conditions exist:
6. If new belts are installed, check the belt
adjustment again after 30 minutes of engine • The belts are worn.
operation at the rated speed.
• The belts are cracked.
7. Close all access covers and access doors.
Secure all access covers and access doors. • The edges of the belts are frayed.
Inspect the hydraulic system for leaks. Inspect the
following components. Repair all leaks.

• Tank
• Cylinder rod seals
• Hoses
 207
Maintenance Section
Wheel Nut Torque - Check

• Tubes i00124062

• Plugs Wheel Nut Torque - Check

• Assembled joints SMCS Code: 4210-535

• Fittings
Inspect the swing drive. Repair all leaks.

Inspect the steering axle, the axle hubs, and the

axle gearbox. Correct any leaks.

Inspect the wheel brakes for oil leaks. Repair any

leaks.

Inspect the transmission for leaks. Correct any

leaks.

Inspect all tires for damage and for proper inflation. g00102965
Illustration 435
Replace any missing valve caps.
Check the torque on the ten wheel nuts on
Inspect the covers for damage and the guards for
each of the four wheels. The torque needs to be
damage. Also make sure that these components
350 to 400 N·m (260 to 300 lb ft). If necessary,
are securely attached.
tighten the wheel nuts.
Inspect the following components for condition and
for cleanliness. Repair the components or clean the i01077829
components, as needed.
Windows - Clean
• Steps
SMCS Code: 7310-070; 7340-070
• Walkways
Use commercially available window cleaning
• Handholds solutions in order to clean the windows. Clean the
outside of the windows from the ground, unless
Inspect the Falling Objects Protective Structure (if handholds are available.
equipped) for damage. Tighten any loose bolts.
Make any necessary repairs.

Inspect the operator’s compartment for cleanliness.

Keep the operator’s compartment clean.

Adjust the rearview mirrors for best visibility.

g00566124
Illustration 436
Typical example

Use a pole with a squeegee in order to reach the

high areas of the window.
208
Maintenance Section
Window Washer Reservoir - Fill

Cleaning Methods
Aircraft Windshield Cleaner Bodily injury can occur from unexpected contact
with open cab doors on machines equipped with
Apply the cleaner with a soft cloth. Rub the window a fixed cab riser.
with moderate pressure until all the dirt is removed.
Allow the cleaner to dry. Wipe off the cleaner with To avoid injury, close the cab door before climbing
a clean soft cloth. onto the rear of the machine.

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.

Stubborn Dirt and Grease

Wash the windows with a good grade of naphtha, of
isopropyl alcohol, or of Butyl Cellosolve. Then, wash
the windows with soap and with water.
g00102266
Illustration 438
i01220995
3. Fill the fluid reservoir through the filler opening
Window Washer Reservoir - Fill on the top of the reservoir. If the machine is
SMCS Code: 7306-544-KE equipped with a lower window wiper/washer, a
second fluid reservoir is mounted in this area.
Fill the second fluid reservoir through the filler
NOTICE opening on the top of the fluid reservoir.
When operating in freezing temperatures, use
Caterpillar or any commercially available nonfreezing 4. Close top access cover (2) and access door (1).
window washer solvent.

i01221005

Window Wiper -
Inspect/Replace
SMCS Code: 7305-040; 7305-510

Inspect the window wiper blades. Replace the wiper

blades if the wiper blades are worn or damaged.
Also replace the wiper blades if the wiper blades
cause streaks.

g00290119
Illustration 437
(1) Access door
(2) Top access cover

1. Open and secure access door (1) on the left

side of the machine.

2. Open top access cover (2).